Wireless tracking of power tools and related devices

ABSTRACT

A power distribution box and method of communicating via the power distribution box are provided. A power input in the power distribution box is coupled to a power output to provide power to external devices. A gateway device supported by the housing of the power distribution box includes a wireless network module for communicating with power tools and a cellular module for communicating via a cellular network with a power tool monitoring system. The gateway may be removable from the power distribution box. A translation controller in the gateway enables communication between the wireless network module and the external network using the cellular module. The translation controller translates messages between the power tools and external network. The messages may include location data or operational data associated with the power tool.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/887,504, filed Feb. 2, 2018, which is a continuation of U.S.application Ser. No.15/266,443, filed on Sep. 15, 2016, now U.S. Pat.No. 9,949,075, which is a continuation of U.S. application Ser. No.14/185,594, filed on Feb. 20, 2014, now U.S. Pat. No. 9,466,198, whichclaims the benefit of U.S. Provisional Patent Application No.61/767,871, filed on Feb. 22, 2013, the entire contents of which arehereby incorporated by reference.

FIELD OF THE INVENTION

The invention relates to systems and methods for wirelessly trackingpower tools and related devices.

BACKGROUND

Theft and misplacement of power tools at job sites and duringtransportation are significant problems for professional power toolusers. Higher costing and higher quality power tools often are subjectto a greater risk of thievery. In some instances, potential buyerschoose lower costing and lower quality power tools to reduce the chancesor impact of theft. Additionally, periodically checking inventory ofsuch tools, for instance, to ensure all tools are returned at the end ofa work day, can be a burdensome and cumbersome process. The burden isparticularly significant for businesses responsible for maintaining alarge corral of tools.

SUMMARY

In one embodiment, the invention provides a power distribution boxincluding a power input, an AC output, a power-line adapter, and agateway device. The power input is configured to receive power from anexternal power source. The AC output is electrically coupled to thepower input and configured to provide power to an external device. Thepower-line adapter is coupled to the power input and configured toreceive power via the power input and to communicate with an externalnetwork. The gateway device is coupled to the power-line adapter andincludes a wireless network module and a translation controller. Thewireless network module is configured to communicate with at least onepower tool device in a wireless network, and the translation controlleris coupled to the power-line adapter and enables communications betweenthe wireless network module and the external network through thepower-line adapter.

In another embodiment, the invention provides a power distribution boxincluding a power input, a first power output, a power-line adapter, anda gateway device. The power input is configured to receive power from anexternal power source. The first power output is electrically coupled tothe power input and is configured to provide power to an externaldevice. The power-line adapter is coupled to the power input and isconfigured to receive power through the power input and to communicatewith an external network. The gateway device is coupled to thepower-line adapter and includes a wireless network module, a cellularmodule, and a translation controller. The wireless network module isconfigured to communicate with at least one power tool device in awireless network and the cellular module is configured to communicatewith the external network through a cellular network. The translationcontroller is coupled to the power-line adapter, the wireless networkmodule, and the cellular module, and it enables communication betweenthe wireless network module and the external network using at least oneof the group including the power-line adapter and the cellular module.

In another embodiment, the invention provides a method of communicatingwith at least one power tool using a power distribution box including apower-line adapter, a gateway device, and AC power outlets. The methodincludes receiving, at a power input of the power distribution box, ACpower from an external power source and distributing the AC powerreceived from the external power source to the AC power outlets. Themethod further includes receiving, via the gateway device, wirelesscommunication from a power tool device including operational dataassociated with the power tool device; transmitting, by the power-lineadapter, the operational data associated with the power tool device toan external network, the external network including a tool monitoringserver; and receiving, at the tool monitoring server, informationregarding the power tool device.

Embodiments of the invention enable a tool tracking system to aid withinventory management and to help minimize, prevent, and recovermisplaced or stolen tools throughout the job site. Other aspects of theinvention will become apparent by consideration of the detaileddescription and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a tool monitoring system according to embodiments ofthe invention.

FIG. 2 illustrates an exemplary tool in the tool monitoring system.

FIGS. 3A and 3B illustrate exemplary monitoring units of the toolmonitoring system.

FIG. 4 illustrates a tool monitoring module according to embodiments ofthe invention.

FIGS. 5A-5D illustrate various graphical user interfaces for use in thetool monitoring system.

FIGS. 6A and 6B illustrate a tool polling method and geo-fence methodaccording to embodiments of the invention.

FIG. 7 illustrates a tool monitoring method according to embodiments ofthe invention.

FIGS. 8A and 8B illustrate alternate embodiments of the tool to bemonitored in the tool monitoring system.

FIGS. 9A and 9B illustrate other devices related to tools that may bemonitored in the tool monitoring system.

FIG. 10 illustrates another tool monitoring system according toembodiments of the invention.

FIGS. 11A-B illustrate communications between elements of the toolmonitoring system of FIG. 10.

FIG. 12 illustrates an exemplary tool of the tool monitoring system ofFIG. 10.

FIGS. 13A-C illustrate an exemplary fob of the tool monitoring system ofFIG. 10.

FIGS. 13D-G illustrate an exemplary ISM phone of the tool monitoringsystem of FIG. 10.

FIG. 14 illustrates an exemplary gateway of the tool monitoring systemof FIG. 10.

FIGS. 15A-B and 16A-E illustrate embodiments of an exemplary gateway ofthe tool monitoring system of FIG. 10.

FIGS. 17A-B, 18, and 19 illustrate embodiments of a combined worksiteradio-gateway for use in the tool monitoring system of FIG. 10.

FIG. 20 illustrates a worksite having an ISM network.

FIGS. 21A-B illustrate puck repeaters according to embodiments of theinvention.

FIG. 22 illustrates an ISM battery in communication with a power tooland an ISM-enabled fob.

FIGS. 23-24 illustrate tethering methods for use with a power tool andpower tool battery.

FIGS. 25A-C illustrate a job box gateway according to embodiments of theinvention.

FIG. 26 illustrates a cross-section A-A of the job box gateway of FIG.25C.

FIG. 27 illustrates a vehicle gateway according to embodiments of theinvention.

FIG. 28 illustrates a two-piece gateway according to embodiments of theinvention.

FIG. 29 illustrate a temporary power distribution system.

FIG. 30 illustrates a power box gateway according to embodiments of theinvention.

FIG. 31 illustrates a cross-section B-B of the power box gateway of FIG.30.

FIG. 32 illustrates another two-piece gateway according to embodimentsof the invention.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

FIG. 1 depicts a tool monitoring system 100 including a tool 105, asatellite 110 (representing a series of global positioning satellites),a cellular network antenna 115 (representing a cellular network), asmart phone 120, the Internet 125, a wireless router 130, a personalcomputer 135, and a tool monitoring server 140. The tool monitoringsystem 100 enables a user to monitor status, usage, and positioninformation of the tool 105 remotely via, for example, the smart phone120 or computer 135.

The tool 105 is a battery-operated power drill that includes a toolcontroller 145, tracking unit 150, sensors 155, battery 160, and a motor165. The tool controller 145 selectively applies power from the battery160 to the motor 165 to cause the motor 165 to rotate in response todepression of a trigger 170. Rotation of the motor 165 is conveyed to anend output unit 175 (e.g., a bit holder), which causes a bit held by theend output unit 175 to rotate to drill a hole in a work piece, drive ina screw, etc. The motor 165 may be a brushless motor, a brushed motor, apermanent-magnet motor, an AC motor, a DC motor, or another type ofmotor.

Although the tool 105 is depicted as a power drill, other types of toolsand accessories may also be monitored by the tool monitoring system 100.For instance, the tool monitoring system 100 may monitor battery packs,battery chargers, other power tools, test and measurement equipment,vacuum cleaners, worksite radios, outdoor power equipment, and vehicles.Power tools can include drills, circular saws, jig saws, band saws,reciprocating saws, screw drivers, angle grinders, straight grinders,hammers, multi-tools, impact wrenches, rotary hammers, impact drivers,angle drills, pipe cutters, grease guns, and the like. Battery chargerscan include wall chargers, multi-port chargers, travel chargers, and thelike. Test and measurement equipment can include digital multimeters,clamp meters, fork meters, wall scanners, IR thermometers, laserdistance meters, laser levels, remote displays, insulation testers,moisture meters, thermal imagers, inspection cameras, and the like.Vacuum cleaners can include stick vacuums, hand vacuums, uprightvacuums, carpet cleaners, hard surface cleaners, canister vacuums, broomvacuums, and the like. Outdoor power equipment can include blowers,chain saws, edgers, hedge trimmers, lawn mowers, trimmers, and the like.The battery pack can also be attachable to and detachable from devicessuch as electronic key boxes, calculators, cellular phones, head phones,cameras, motion sensing alarms, flashlights, worklights, weatherinformation display devices, a portable power source, a digital camera,a digital music player, a radio, and multi-purpose cutters.Additionally, the tool monitoring system 100 is operable to monitormultiple devices simultaneously.

The sensors 155 detect various status and usage information from thetool 105. For instance, the sensors 155 may include a motor sensor totrack the number of motor rotations and to detect motor rotation speedand acceleration; a torque sensor to detect motor torque; a batterysensor to detect the battery charge level and the rate of increase ordecrease of the battery charge level; a trigger sensor to detect whetherthe trigger is depressed; an acceleration sensor to detect movement ofthe tool, including abrupt decelerations (e.g., caused by dropping); anda temperature sensor to detect the temperature within the tool housing.

The tool controller 145 is in communication with the sensors 155 toreceive the obtained sensor data from the sensors 155 and to control theoperation of the sensors 155 (e.g., to enable or disable particularsensors). The tool controller 145 includes a memory 180 (see FIG. 2) tostore the sensor data for later export from the tool 105, as will bedescribed in greater detail below.

The battery 160 is a removable, rechargeable energy storage device thatprovides power to the components of the tool 105. The battery 160 maycomprise electrochemical cells that convert stored chemical energy intoelectrical energy. For instance, the battery 160 may include lithiumion, nickel-metal hydride, and/or nickel-cadmium cells. Other batterycells may also be used. The battery 160 includes a base 160 a andprojection 160 b including a positive and a negative electrical contact.The projection 160 b slides into a receiving cavity in the bottom handleof the tool 105 and locks into engagement with the tool 105 such thatthe battery 160 remains engaged with the tool 105 unless a release tab(not shown) is actuated. In some embodiments, other battery connectionsand configurations are possible for the tool 105 including an internal,non-removable battery.

The tracking unit 150 of tool 105 includes one or more antennas 185 forcommunication with the satellite 110, cellular network antenna 115,wireless router 130, and/or other wireless communication networks anddevices. Turning to FIG. 2, the antennas 185 include a cellular antenna190, a WLAN antenna 195, and a global positioning system (GPS) antenna200, which are associated with a cellular unit 205, WLAN unit 210, andGPS unit 215, respectively. In some embodiments, the WLAN antenna 195and WLAN unit 210 facilitate wireless communication according to IEEE802.11 protocols, also referred to as Wi-Fi®. In some embodiments, otherantennas may be included in addition to or in place of the antennas 185to enable other types of wireless communication (e.g., Bluetooth™, radiofrequency identification (RFID), satellite phone, etc.) and the trackingunit 150 may also include wired connection interfaces (e.g., UniversalSerial Bus (USB), FireWire®, etc.) for communicating with other devices(e.g., smart phone 120, PC 135, and tool monitoring server 140).Accordingly, the WLAN and cellular communications described below thatoccur between the tool 105 and remote devices (e.g., smart phone 120, PC135, and tool monitoring server 140) may also be carried out by way ofthe other types of wireless and wired communication interfaces.

Rotating of the motor 165 may cause interference that is detrimental toperformance of one or more of the antennas 185. Accordingly, in someembodiments, if the motor 165 is rotating, transmissions from thetracking unit 150 are delayed until rotation has ceased. However, if thetransmissions are high priority, for instance, to indicate a possibletheft of the tool 105, the transmissions are not delayed until rotationof the motor 165 ceases. Additionally, if the motor 165 rotates for aprolonged, uninterrupted period, particularly if the battery 160 is low,the transmissions of the tracking unit 150 are not delayed untilrotation of the motor 165 ceases. Moreover, the antennas 185 may bepositioned in the tool 105 away from potential sources of interference,such as the motor 165. For instance, the antennas 185 may be positionedat the base of the handle of tool 105. Furthermore, one or more of theantennas 185 may be integrated with a housing or gear case within thetool 105 to improve transmission and reception performance.

The tracking unit 150 further includes a controller 220 in communicationwith the cellular unit 205, WLAN unit 210, GPS unit 215, and a memory225. The memory 225 may store instructions that, when executed by thecontroller 220, enable the controller 220 to carry out the functionsattributable to the controller 220 described herein. Although thetracking unit 150 is generally powered by the battery 160, in someinstances, an additional energy storage device 230 is included. Theadditional energy storage device 230 enables the tracking unit 150 tooperate even when the battery 160 is not inserted into the tool 105.That is, if the battery 160 is not present in the tool 105, or if thebattery 160 is below a low power threshold, the tracking unit 150 mayoperate based on power from the additional energy storage device 230.For instance, the controller 220 may receive an indication from the toolcontroller 145 that the battery 160 is not present or below a low powerthreshold. In turn, controller 220 is operable to open or close a switch(not shown) to connect the energy storage device 230 to the othercomponents of the tracking unit 620.

The additional energy storage device 230 may be a non-rechargeable,primary battery that is generally not removable from the power tool 105,except during repairs or the like. In some instances, the primarybattery is designed to have a life expectancy of between about five toseven years. For instance, the primary battery may be soldered orotherwise mounted to a printed circuit board that includes othercomponents of the tracking unit 150. In some embodiments, the additionalenergy storage device 230 is a rechargeable battery (e.g., lithium ion)and/or an ultra capacitor. In some embodiments, in combination or inplace of the other power sources, the tracking unit 150 may be poweredby a solar cell mounted externally on the tool 105 and/or a fuel cellwithin the tool 105.

The controller 220 is also in communication with the tool controller145, for instance, to retrieve tool status and usage data, such as thatwhich is stored in the memory 180 or being obtained by the toolcontroller 145 (e.g., from the sensors 155) in real-time or nearreal-time.

In operation, the tracking unit 150 receives global positioningsatellite (GPS) signals via the GPS antenna 200 from satellite 110. TheGPS signals are transmitted from the GPS antenna 200 to the GPS unit215. The GPS unit 215 interprets the GPS signals to determine a positionof the tracking unit 150. The determined position is output by the GPSunit 215 to the controller 220 as position data. The controller 220 alsoobtains tool status and usage data (whether from memory 225 or toolcontroller 145) which, in combination with the position data, iscollectively referred to as “tool data.” The controller 220 then outputsthe tool data to the cellular unit 205. The cellular unit 205, via thecellular antenna 190, is operable to convert the position data to anappropriate format and transmit the position data to a remote cellulardevice, such as smart phone 120, via the cellular network antenna 115.In some instances, the remote cellular device is a base station (notshown) that converts the cellular transmission to another communicationprotocol, such as an Internet-compatible protocol, WLAN, Bluetooth,etc., for transmission to a remote monitoring device (e.g., smart phone120, PC 135, or server 140). The cellular unit 205 may transmit theposition data to the cellular network antenna 115 in a format compatiblewith an analog cellular network, a digital cellular network (e.g.,Global System for Mobile Communications (GSM), Code Division MultipleAccess (CDMA), High-Speed Downlink Packet Access (HSDPA), Short MessageService (SMS)), as well as other cellular network protocols.

In addition to, or as an alternative to, the controller 220 outputtingthe tool data via the cellular unit 205, the controller 220 may alsooutput the tool data via the WLAN unit 210. The WLAN unit 210 convertsthe tool data to a WLAN-compatible format and transmits the tool data toa remote device, such as a tool monitoring server 140, PC 135, orinternet-enabled smart phone 120, via the wireless router 130. In someembodiments, the wireless router 130 facilitates wireless communicationaccording to IEEE 802.11 protocols, also referred to as Wi-Fi®. In someinstances, the wireless router 130 may be a type of wireless accesspoint (WAP) device other than a router, such as a hub.

In some embodiments, the GPS unit 215 is an assisted GPS (aGPS) unitthat communicates with the cellular unit 205 and/or WLAN unit 210 inaddition to monitoring GPS radio signals to determine the position ofthe tool 105. For example, the aGPS unit may communicate with remotedevices (not shown) via the cellular unit 205 and/or WLAN unit 210 toobtain information that assists in more quickly acquiring satellites.The information may include orbital data for GPS satellites (e.g.,satellite 110), precise time data, position information based ontriangulation between cellular towers (e.g., cellular network antenna115) or WLAN routers (e.g., wireless router 130), etc. In someinstances, the GPS unit 215 may transmit GPS signal data received viathe GPS antenna 200 to a remote GPS server (not shown) via the cellularunit 205 or WLAN unit 210. The GPS server is then operable to generatethe position data and provide the position data back to the GPS unit215, controller 220, or a remote monitoring device. In some embodiments,the tracking unit 150 determines the position of the tool 105 usingcellular triangulation, rather than using the GPS unit 215.

FIG. 3A illustrates the smart phone 120, an exemplary remote monitoringunit, in greater detail. The smart phone 120 includes a processor 250for executing instructions (e.g., stored in memory 252) for carrying outthe functionality of the smart phone 120 as described herein. Theprocessor 250 is in communication with a display 254 for providing agraphical user interface (GUI) to a user of the smart phone 120. Theprocessor 250 is further in communication with a cellular unit 256, GPSunit 258, and WLAN unit 260. The cellular unit 256 is coupled to acellular antenna 262 and, in combination, they enable the smart phone120 to communicate via a cellular network (e.g., via cellular networkantenna 115). The GPS unit 258 is coupled to GPS antenna 264 to receiveGPS signals and enable the smart phone 120 to determine its position.The WLAN unit 260 is coupled to a WLAN antenna 266 and, in combination,they enable the smart phone 120 to communicate via a WLAN network (e.g.,via wireless router 130). In some embodiments, the WLAN antenna 266 andWLAN unit 260 facilitate wireless communication according to IEEE 802.11protocols, also referred to as Wi-Fi®. In some embodiments, like the GPSunit 215, the GPS unit 258 is an assisted GPS (aGPS) unit that usescommunications from the cellular unit 256 and WLAN unit 260 to improvethe GPS position locating functionality.

The smart phone 120 further includes a tool monitoring module 270. Thetool monitoring module 270 includes software and/or hardware forcarrying out the functionality of the tool monitoring module 270described herein. Additionally, although shown in FIG. 3A separately, insome embodiments, the tool monitoring module 270 is combined with theprocessor 250, memory 252, and other components of the smart phone 120.For instance, the tool monitoring module 270 may be an application, or“app,” downloaded or otherwise installed on the memory 252 and executedby the processor 250 of the smart phone 120 or PC 135. The toolmonitoring module 270 will be described in more detail with respect toFIG. 4 below.

Turning to FIG. 3B, the PC 135 is illustrated in greater detail. The PC135 includes several components similar to the smart phone 120, and,accordingly, these components are numbered alike. The PC 135 may be adesktop computer, laptop computer, tablet computer, or other computingdevice that generally does not include a cellular antenna. The PC 135includes an Ethernet unit 272 and Ethernet port 274 for receiving anEthernet cable to enable the PC 135 to communicate via a wiredconnection to the Internet 125. Although not shown in FIGS. 3A or 3B,additional input and output devices may be coupled to the smart phone120 and PC 135, such as speakers, an auxiliary display, a keyboard, amouse, disk drives, etc.

FIG. 4 illustrates the tool monitoring module 270 in greater detail. Thetool monitoring module 270 enables a monitoring unit (e.g., smart phone120, PC 135, and server 140) to remotely monitor, communicate with, andcontrol the tool 105. The tool monitoring module 270 includes a toolpolling module 275, a tool database 285, a geo-fence module 290, a toolsecurity module 295, and a chirp module 297.

The tool database 285 stores information about the tools to bemonitored, such as tool 105. The tool database 285 includes a tool IDsdatabase 285 a and tool information database 285 b. The tool IDsdatabase 285 a includes identifying information for each tool beingmonitored. For instance, for tool 105, the tool IDs database 285 a maystore one or more of a tool serial number, contact addresses/numbers forcommunicating with the tool 105 (e.g., a phone number for the cellularunit 205 or an IP address), owner information (e.g., the name of abusiness that is registered as owner of the tool and contactinformation, such as a phone number or email address), the type of tool(e.g., hammer drill), the model number of the tool 105, and userinformation (e.g., name, contact information, job title, licensing, andskill level). The tool information database 285 b stores informationobtained from the tools through monitoring, including the tool data(i.e., tool status, usage, and position data). The tool informationdatabase 285 b may store a history of tool data obtained over time foranalysis by an owner, tool manufacturer, or tool maintenance personnel.

FIG. 5A depicts the smart phone 120 including the display 254, a speaker300, a microphone 302, and a keypad 304. The display 254 is a touchscreen display depicting a GUI 306 produced by the tool monitoringmodule 270 in conjunction with the other components of the smart phone120. Although the GUI 306 is described above with respect to the smartphone 120, the GUI 306 may also be implemented on the PC 135 or anotherremote monitoring device.

The GUI 306 includes a tool list 310 that lists the tools of tooldatabase 285. The user may enter a tool ID or other tool characteristics(e.g., the tool properties stored in tool database 285) in the searchtool bar 312 to locate a particular tool in the tool database 285. Insome instances, the user can apply filters to (e.g., tool type, toollocation, owner, etc.) and sort the tools in the tool list 310. The usermay touch one or more tools displayed in the tool list 310 to selectparticular tools, or may touch the “all” button 314, group A button 316,or group B button 318. The user may assign a particular set of tools(e.g., all drills, or all tools at a particular worksite) to the group Abutton 316 and group B button 318. For instance, one technique forassigning tools includes a user highlighting multiple tools within thetool list 310, then touching the group A button 316 for predeterminedamount of time (e.g., 5 seconds). After an assignment, the user mayquickly select a particular set of tools by touching the group A button316 and group B button 318. The GUI 306 also includes an obtain tooldata button 320, a locate button 322, a set geo-fence button 324, alock/unlock button 326, and a map button 328, which are described belowin further detail. In general, however, the actions taken as a result oftouching one of the buttons 320-328 are applied to the one or more toolsof tools list 310 that have been selected by a user. Further, a separatechirp button (not shown) may be included on the GUI 306 to activate thechirp module 297. Alternatively, the locate button 322 may be used toactivate the chirp module 297, which is described below.

After selecting one or more tools, the user may poll the selectedtool(s) by touching the obtain tool data button 320, which initiates amethod 340 for polling monitored tools (see FIG. 6A). In step 345, thetool polling module 275 receives the user request via a GUI 306, whichspecifies the tools to be polled. In step 350, the tool polling module275 accesses the tool IDs database 285 a to obtain contact informationfor each tool to be polled. In step 355, the tool polling module 275outputs a polling command to the requested tools. The polling command issent according to the obtained contact information. For instance, thepolling command may be transmitted via cellular network antenna 115 tothe cellular unit 205 of the tool 105 and/or via the Internet 125 andwireless router 130 to the WLAN unit 210 of the tool 105. In someinstances, the tool database 285 is stored remotely (e.g., on toolmonitoring server 140). In these instances, identifiers for the selectedtools are sent to the tool monitoring server 140, which locates the toolcontact information and returns the tool contact information to the toolpolling module 275 or transmits the polling command to the appropriatetools.

Once the poll command is received by the tool 105, the controller 220 ofthe tool 105 gathers tool data for transmission. The controller 220 maygather new tool data or may assemble the most recently gathered tooldata (i.e., tool data gathered before the poll command was received).The gathered tool data is then output back to the requesting toolpolling module 275 via one of the various available communication paths.In step 360, the tool polling module 275 receives the tool data sent bythe tool 105, including the tool ID, position data, status data, andusage data. In step 365, the tool polling module 275 displays thereceived tool data to the user on the GUI 306 and/or stores the receivedtool data in the tool information database 285 b.

Turning back to FIG. 5A, the user may also touch the locate button 322to obtain just the position data of the selected tools. In theseinstances, the method 340 is performed, but only position data isgathered and transmitted by the tool 105, not the tool status and usagedata. Once the position data is received, whether from the locate button322 or obtain tool data button 320, the GUI 306 may indicate thelocation of the selected tools on a map and/or update the locationcharacteristic of the tool list 310. The location characteristic of thetool list 310 indicates whether a tool is within a geo-fence (“onsite”), in a warning area of the geo-fence (“warning”), or outside ofthe geo-fence (“off site”). If the user touches the map button 328, theGUI 306 displays a mapping of the selected tools based on the obtainedposition data. For example, as shown in FIG. 5B, the GUI 306 isdisplaying a map 370 including tools 105 a and 105 b based on theirassociated position data. The tool monitoring module 270 mayautomatically update the map 370 by periodically requesting positiondata from the tools 105 a and 105 b. The user may specify the updatingperiod to be short to provide a real-time map, or to be longer toconserve battery power and reduce data transmission rates.

The user may select a chirp button (not shown) of the GUI 306, or, insome instances, selecting the locate button 322 initiates the chirpfeature. Selecting the chirp button causes the chirp module 297 toreceive a chirp request specifying the tool(s) currently highlighted inthe GUI 306. The chirp module 297 accesses the tool IDs database 285 ato obtain contact information for each tool to chirp. The chirp module297 then outputs a chirp message to the specified tools. Upon receipt bythe tool 105, the tool 105 outputs a chirp noise or other audible soundto assist the user in locating the tool 105. The tool 105 may repeatedlyoutput the chirp noise to guide the user for a preset amount of time inresponse to the chirp message. Once the user locates the tool 105, theuser may depress the trigger or another button on the tool 105 to ceasethe chirp noise. In some embodiments, the tool 105 includes a light thatflashes and/or a vibration element that vibrates in combination with orin place of the chirp noise to assist the user in locating the tool 105.In some embodiments, the user may select via the GUI 306 whether thetool 105 is to output an audible indicator (e.g., chirp), a visualindicator (e.g., light flash), a tactile indicator (e.g., vibration) ora combination thereof, in response to the chirp message. In someembodiments, the tool 105 stores an audio message in the memory 225 orthe memory 180 that indicates the owner of the tool 105. Upon receivingan owner request, the tool 105 outputs the audio message (e.g., “Thistool is owned by Acme Company”). In some instances, the owner request ismade by a user via an owner request button (not shown) of the GUI 306 orby depressing a button on the tool 105.

To set a geo-fence, the user selects one or more tools via the GUI 306as described above, and touches the set geo-fence button 324. FIG. 6Billustrates a method 375 of implementing a geo-fence. In step 380, thegeo-fence module 290 receives tool IDs that identify the tools for whichthe user desires to set geo-fence boundaries. For example, the user mayhighlight tools in the tool list 310 and touch the set geo-fence button324 to select the tools for setting a geo-fence. In step 382, thegeo-fence module 290 receives geo-fence boundaries for the selectedtools. In some embodiments, step 382 includes the GUI 306 displaying amap 385, as shown in FIG. 5C. The user may focus the map 385 on aparticular area, such as the worksite where the selected tools will beused, using pan and zoom controls 390. Thereafter, the user may drawboundaries by first touching a GUI drawing instrument 395, then dragginga pointer around the map 385 to create boundary 397. Using the GUIdrawing instrument 395 to create boundary 397 allows custom boundariesfor worksites that are irregularly shaped, that are spread acrossstreets, etc. The user may then indicate when the boundaries have beencompleted via the keypad 344 or another software button of GUI 306.Other boundary-drawing techniques, such as the placement and re-sizingof a circle, square, or other shapes, may also be used in step 380. Oncethe boundaries are received, they are associated with the tool IDsobtained in step 380 and stored in geo-fence module 290.

In step 400, the geo-fence module 290 receives tool position dataassociated with tool IDs, for instance, using the method 340 describedabove. In step 405, the geo-fence module 290 compares the position datafor a particular tool with the previously set boundary, and determineswhether the tool is within the boundary. If the tool is within theboundary, the location characteristic of the tool is updated to indicatethat the tool is “on site.” If the tool is outside of the boundary, thelocation characteristic of the tool is updated to indicate that the toolis “off site.” In some embodiments, a warning buffer is added to theboundary such that when the tool is near, but has not yet exceeded, theboundary (e.g., within 2 meters), the location characteristic is updatedto indicate a warning. Although not shown, the size of the warningbuffer may be specified via the GUI 306. The location characteristic maybe stored in tool database 285 or the geo-fence module 290 and isdisplayed in the tool list 310, as shown in FIG. 5A.

In step 410, the geo-fence module 290 determines whether to take actions(i.e., security actions) in response to the determination of step 405.For example, as shown in FIG. 5B, tool 105 a is within the boundary 397(on site), and tool 105 b is outside of boundary 397 (off site). For atool determined to be off site, such as tool 105 b, the geo-fence module290 may automatically send a lock signal to the tool 105 b (e.g., viathe cellular network antenna 115 or wireless router 130). In response,the tool 105 b disables itself to prevent further use of the tool 105 buntil the tool 105 b is unlocked, either manually via lock/unlock button326 or upon the tool 105 b returning within the set boundary. To disablethe tool 105 b, the tool controller 145 may disconnect the battery 160from the motor 165 by opening or closing one or more particular relaysor switches (e.g., MOSFETs) as appropriate, or by taking anotherdisabling action.

Another security action includes a limp mode in which performance of thetool 105 is degraded. For instance, the power output of the tool 105 maybe reduced by the tool controller 145. In the case of a brushless motor,the power reduction may be accomplished by changing the timing and/orduration of FET driving signals. Additionally, the period of continuousoutput by the tool 105 may be limited, for example, to one or a fewseconds. In the limp mode, a user is made aware that the tool 105 stillfunctions, albeit at a reduced level. Thus, the user can infer that asecurity action has taken place, rather than a malfunction of the motorof the tool 105 or a drained battery. Additionally, a visual (e.g., alimp mode light), audible (e.g., a beep), or tactile signal may beprovided to the user by the tool 105.

Another exemplary security action includes automatically debiting anaccount. For instance, a user may be responsible for a particular tool105, and if the tool 105 exceeds the boundary 397, a monetary or creditaccount of the user may be automatically deducted or charged. Anothersecurity action includes automatically populating a report (e.g., anelectronic document) with information relating to the breach of theboundary 397, including the tool type, serial number, the date and timeof the breach, the last known location and heading of the tool 105,owner contact information, etc. The report may then be sent togovernment authorities and/or one or more contact entities associatedwith the tool 105 according to information stored in the tool database185 or a memory within the tool 105.

In some embodiments, the security action is delayed for a particularperiod of time. For instance, the security action may be delayed for aparticular period of time (e.g., a few minutes, hours, days, etc.), oruntil a particular action (e.g., removing the battery, inserting a newbattery, releasing or depressing the trigger, etc.). Accordingly, if thetool 105 returns within a boundary before the delayed security action isenacted, the security action is cancelled. This delayed action preventsthe tool 105 from being locked-out, put in limp mode, etc., momentarilybased on wireless outages or temporary movements outside of a geo-fence.

As described above, a geo-fence may be set for a plurality of tools. Insome embodiments, one or more thresholds are associated with such ageo-fence. For instance, the user may set a threshold at four tools,such that, upon four monitored tools 105 exceeding the boundary 397, oneor more security actions are taken (e.g., locking the tools, alertingthe owner(s), etc.). Alternatively, the threshold may be a monetarylimit and each tool may be assigned a monetary value. Accordingly, whenthe sum of the tools 105 outside of the boundary 397 exceeds themonetary threshold (e.g., $1000), one or more security actions aretaken. Furthermore, in some embodiments, multiple thresholds are set andthe security actions taken in response to a particular threshold beingexceeded depends on which threshold is exceeded. For instance, if onetool 105 exceeds the boundary 397, the tool 105 is locked. If two tools105 exceed the boundary 397, the tools 105 are locked, and a primarycontact (e.g., an on-site supervisor) is contacted via a text message,email, or phone call. If five tools 105 exceed the boundary 397, primaryand secondary contacts (e.g., off-site supervisors or management) arecontacted. If ten tools 105 exceed the boundary 397, in addition to theother security actions, the authorities are contacted. The varioussecurity actions may be performed by the tool 105, a remote monitoringunit (e.g., PC 135), or a combination thereof.

A time-component may also be associated with a boundary threshold. Thesecurity actions taken may vary depending on the threshold that isexceeded. For instance, if a large number of tools are moved outside ofthe boundary 397 nearly simultaneously (e.g., twenty tools within fiveminutes of each other), it could indicate that a large theft may be inprogress, and authorities (i.e., the police) may be contacted. If amodest number of tools exceed the boundary over the course of a week, anemail or text message may be sent to the owner to indicate a summary ofthe activity and possibly highlight long-term trends. Additionally,security actions taken in response to exceeded thresholds may varydepending on the time of day. For instance, if a worksite is generallyonly operating during the day (e.g., 7:00 am to 5:00 pm), but a tool ismoved beyond the boundary 397 at midnight, authorities may be contactedimmediately and the owner may be called with an automatic voice message.In contrast, if a tool is moved beyond the boundary 397 at noon, theowner may receive a text message, and authorities are not immediatelycontacted.

Additionally, the geo-fence module 290 may automatically send an alarmsignal to the tool 105 b. In response, the tool 105 b may vibrate, soundan audible alarm, or take other actions to indicate to the user that thetool 105 b has exceeded the set boundary. Additionally, the geo-fencemodule 290 may automatically send an alarm to the owner of the toolusing contact information from the tool IDs database 285 b. Forinstance, the geo-fence module 290 may cause a text message, automatedvoice message, email, page, etc. to be sent to the owner to indicatethat the tool 105 has exceeded the set boundary. The owner may thendetermine whether to take actions, such as to call authorities (in thecase of theft), lock or unlock the tool 105 b, etc. In some instances,upon determining that the tool 105 b is approaching a boundary (e.g., awarning zone), the geo-fence module 290 sends a warning message to theowner and/or a warning signal to the tool 105 b to cause the tool 105 bto vibrate or sound an audible warning alarm.

FIG. 5D illustrates the GUI 306 with an alternate technique for defininga boundary for a geo-fence in step 380. After receiving tool IDs in step380, the GUI 306 displays screen 415 including a center point 420. Inthis alternate technique, the boundary takes a regular shape, such as acircle, square, or a polygon, and is centered on center point 420. Theuser selects the boundary shape by touching one of the shapes 425, andselects the radius of the boundary shape by selecting or specifying oneof the ranges 430 or by dragging the boundary perimeter. In FIG. 5D, theuser has selected a circle shape with a radius of 100 m. Although notdepicted, the user may also select a distance between the boundary 435and the warning boundary 440.

Additionally, the boundaries 435 and 440, as well as the positions ofthe tools, may be overlaid on a map similar to map 385. Accordingly, thecenter point 420 may be dragged to an appropriate map position by auser. Alternatively, the center point 420 may be the location of astreet address or geographic coordinates (i.e., longitude and latitude)entered by the user, such as the address or coordinates of a warehouse,a factory, a construction site, etc. In some embodiments, the centerpoint 420 is tied to a GPS-enabled device that can periodically reportits GPS coordinates and, therefore, the position of the center point 420may be dynamic. For example, the GPS-enabled device may be a cell phoneof a construction site supervisor, a vehicle, a tracking device securedto a construction-site headquarters or trailer, or another device. Insome embodiments, the center point 420 is tied to another tool 105 suchthat the geo-fence boundary for one or more tools 105 is centered aboutthe location of another tool 105.

Returning to FIG. 4, the tool security module 295 is operable to limp,unlimp, lock or unlock the tool 105 and to cause an alarm to activate onthe tool 105. For instance, in response to the tool 105 exceeding ageo-fence boundary, or in response to user selection of the lock/unlockbutton 326, the tool security module 295 may lock or unlock the tool105.

The tool monitoring module 270 is also operable to communicate via oneof the various communication networks (e.g., the cellular networkantenna 115 or the Internet 125) software or firmware updates to thetool 105 to update the tool 105 remotely. For instance, if a newfirmware update is provided by the tool manufacturer, the tool owner mayremotely install the firmware update on the tool 105. Remote updatingallows the tools to remain in the field and avoids the need to bring thetool to a manufacturer or maintenance person.

FIG. 7 illustrates a method 450 of monitoring a tool (e.g., tool 105)whereby the tool self-reports tool data independent of polling commandsfrom a remote monitoring device. Accordingly, tool 105 periodically andautomatically determines when the tool 105 has exceeded a geo-fenceboundary, has a low battery, or has maintenance issues, and reports thedetermination to the remote monitoring device.

In step 455, the tool 105 receives a geo-fence boundary from the toolmonitoring module 270. For instance, the geo-fence boundary is enteredby a user using one of the above-noted techniques, and transmitted tothe tracking unit 150. The user may also specify a particular reportingtime (e.g., every 10 seconds, every 10 minutes, every hour, etc.) forthe tracking unit 105 to provide tool data back to the tool monitoringmodule 270. In step 460, the tracking unit 150 sets a timer according tothe specified reporting time or, if none was provided, uses a defaulttime. In step 465, the tracking unit 150 determines if the timer haselapsed, which will not be the case in the first iteration.

In step 470, the tracking unit 150 obtains position data, status data,and usage data as described above. In step 475, the tracking unit 150compares the position data to the geo-fence boundary received in step455. If the boundary has been exceeded, in step 480, the tracking unit150 causes the tool 105 to be locked and sets off an alarm (e.g.,audible, tactile, or visual) to notify the tool user that the boundaryhas been exceeded. Additionally, the tracking unit 150 proceeds to step485 and outputs the tool data to the tool monitoring module 270,including an indication that the boundary has been exceeded and the toolserial number or other identifier. The tool monitoring module 270 maythen take the appropriate actions, such as notify the owner and/orauthorities. By including the serial number of the tool 105 or otheridentifying information specific to the tool 105, along with theposition data, the owner of the tool 105 may more easily prove to theappropriate authorities that he or she is the true owner of the tool105.

In some embodiments, in addition to or instead of checking-in with thetool monitoring module 270 after a boundary or warning boundary has beenexceeded, the tracking unit 150 may send a text message, automated voicemessage, email, page, or other communication directly to a contactperson associated with the tool 105 (e.g., the owner), to indicate thatthe tool 105 has exceeded the set boundary and to provide the toolserial number. The serial number of the tool 105 may be stored in memory225 of tracking unit 150, as well as the contact information (e.g.,phone number or email address) for the contact person. The contactinformation may be remotely updated via the tool monitoring module 270.

If the geo-fence boundary has not been exceeded, in step 490, thetracking unit determines whether the geo-fence warning boundary has beenexceeded (e.g., boundary 435 of FIG. 5D), which may also be received instep 455. If the geo-fence warning boundary has been exceeded, thetracking unit 150 may issue a warning in step 495 (e.g., sound anaudible alarm, cause the tool to vibrate, etc.), and then proceeds tostep 485 to output tool data to the tool monitoring unit 270, includingan indication that the warning boundary has been exceeded.

If neither geo-fence boundary has been exceeded, the tracking unit 150proceeds to step 500 where all alarms and tool lock-outs remain disabledor become disabled. Thus, if tool 105 momentarily exceeds the geo-fenceboundary, the tool 105 will initially be locked, but the tool 105 willbe unlocked upon returning within the geo-fence boundary. In someembodiments, the tool 105 remains locked out until a reset action by thetool monitoring module 270 or other reset action.

In step 505, the tracking unit 150 determines whether the state ofcharge of the battery 160 has dropped below a low level threshold. Ifthe battery 160 is low, the tracking unit 150 proceeds to step 510 wherethe timer length used in step 515 during a timer reset is increased to asecond, longer timer. The longer timer reduces the amount of reportingby the tracking unit 150 to conserve energy. In some instances, inresponse to user preferences, step 510 is bypassed and the timer is notchanged. In some embodiments, other power reduction techniques may alsobe used. For instance, movement data from an accelerometer of the tool105 may be used to reduce the rate of communications from the tool 105.For instance, if the accelerometer indicates that the tool 105 has notmoved recently, the tool 105 does not determine or output location data,since the location data would be duplicative of the previous output.This determination may be made after step 465 and before step 470. Forinstance, after the timer is determined to have elapsed in step 465, thecontroller 220 determines whether movement has occurred since theprevious timer expiration. If movement has occurred, the method proceedsto step 470; if not, the method returns to step 460 to reset the timer.

After optionally adjusting the timer length in step 510, the trackingunit 150 determines whether the low battery status has previously beenreported to the tool monitoring module 270. If the low battery statushas not been previously reported, the tracking unit 150 reports the lowbattery along with the other tool data to the tool monitoring module 270in step 485. If the low battery status has already been reported, thetracking unit returns to step 465.

In step 525, the tracking unit 150 determines whether a maintenanceissue is present on the tool 105. For example, the tool controller 145or controller 220 may monitor the use of tool 105 and determine it isdue for a standard check-up based on total hours in operation.Additionally, the tool controller 145 may determine that the tool isoverheated based on output from sensors 155, or some other mechanicalissue is present. If a maintenance issue is determined to exist in step525, the tracking unit 150 will report the issue to the tool monitoringmodule 270, unless the issue has already been reported as determined instep 520.

Although described above as being executed by the tool 105, the method450 may be adopted for execution by the tool monitoring module 270 ofthe smart phone 120 or PC 135. For instance, the tool monitoring module270 may carry out steps 455-465, then, in step 470, poll the tool 105(see e.g., method 340) to obtain tool data. The tool monitoring module270 uses the obtained tool data to carry out the decision steps 475,485, 505, and 525, and executes the remaining steps of method 450accordingly, except that the tool check-in step 485 is no longernecessary, as the tool monitoring module 270 has already obtained thetool data.

FIGS. 8A-8B depict alternate embodiments of the tool 105. In FIG. 8A, atracking unit 550 is secured to the external housing 555 of a tool 560.The tool 560 is similar to tool 105, and the tracking unit 550 issimilar to the tracking unit 150, except as noted below. The trackingunit 550 includes a battery 565 for powering the tracking unit 550, anda mount 570 for securing the tracking unit 550 to the external housing555 of the tool. The tracking unit 550 and tool 560 are not drawn toscale, and, in practice, the tracking unit 550 would be positioned insuch a way as to avoid obstructing an operator of the tool 560. In someembodiments, the tracking unit 550 would be mechanically coupled to thetool 560, but not electrically. Thus, the tracking unit 550 is able toreport position data, but not communicate with the sensors 155 to obtainstatus and usage data and not able to receive battery power from thebattery 160. The tracking unit 550 may include sensors, however, forgathering status and usage data measurable from outside of the housing555 (e.g., temperature, vibrations, etc.) The external tracking device550 may be mounted to other devices as well, such as a battery charger,battery pack, work-site radio, vehicle, ladder, or constructionmaterials.

The tracking unit 550 may be programmed via a wireless or wiredconnection such that the tracking unit 550 stores the type of tool ordevice to which it is secured. (e.g., drill, battery charger, ladder,vehicle, etc.) For instance, the smart phone 120 or monitoring device135 may include software for communicating with and programming thetracking unit 550. Thereafter, when transmitting the ID of the trackingunit 550, the tracking unit 550 may also identify to a receiving devicethe type of tool or device to which it is attached.

FIG. 8B depicts a tool 575 that receives AC power from an AC mainsoutlet 580. The tool 575 is similar to tool 105 except as noted below.The tool 575 includes a rectifier 585 for converting the received ACpower to DC power for powering the internal circuitry of the tool 575,such as tracking unit 150, tool controller 145, and sensors 155. In someembodiments, the motor 165 is powered by AC power, while, in otherembodiments, the motor 165 is powered by DC power. In tool 575, thetracking unit 150 includes the optional energy storage device 230 toenable the tracking unit 150 to operate even when the tool 575 is notcoupled to the AC mains outlet 580, similar to the tracking unit 150 oftool 105 operating when the battery 160 is removed. For instance, thecontroller 220 may detect from the tool controller 145 that the tool 575is not receiving power from the AC mains outlet 580. In turn, thecontroller 220 may close or open a switch to connect the energy storagedevice 230 to the other components of the tracking unit 150.

FIGS. 9A-9B depict devices related to power tools in which a trackingunit 150 may be used. FIG. 9A depicts a battery 590 with a projection591 and base 592. The stem includes electrical contacts 594 for engagingcontacts of a receiving tool or other device (e.g., a work-site radio).A battery controller 593 is within the battery 590. The batterycontroller 593 is operable to monitor one or more of the state-of-chargeof the battery, current charge/discharge rate, temperature, and otherbattery characteristics. The battery controller 593 is also operable tocommunicate with a tool or device. For example, the battery controller593 may communicate via the electrical contacts 594 the monitoredbattery characteristics and an identifier that identifies, for example,the type and capacity of the battery 590. The battery controller 593 mayalso receive tool status and usage data from the tool. The tracking unit150 operates as described above with respect to tool 105. Accordingly, aremote user is able to locate and monitor the battery 590 via the toolmonitoring module 270, as well as receive information about the deviceto which the battery 590 is coupled.

FIG. 9B depicts a battery charger 595 with a slot 596 for receiving abattery projection (e.g., battery 160 b or 591) and a plug 597 forcoupling the battery charger 595 to an AC mains outlet. Within the slotare electrical contacts (not shown) for engaging contacts of an insertedbattery. A charger controller 598 is within the battery charger 595 tocontrol the charging and discharging of an inserted battery. The chargercontroller 598 is also operable to monitor characteristics of thecharger 595 and an inserted battery. For example, the charger controller598 monitors the state of charge of an inserted battery, the rate ofcharge/discharge, temperature, etc. The tracking unit 150 operates asdescribed above with respect to tool 105, except that thecharacteristics monitored by the charger controller 598 arecommunicated, rather than tool status and usage data. Accordingly, aremote user is able to locate and monitor the battery charger 595 viathe tool monitoring module 270.

FIG. 10 depicts a tool monitoring system 600 that utilizes industrial,scientific and medical (ISM) band communications. The system 600includes tools 605, a key fob 610, and a gateway 615, along with thesatellite 110, the cellular network antenna 115, the smart phone 120,the Internet 125, the personal computer 135, and the tool monitoringserver 140 described above with respect to FIG. 1. The tool monitoringsystem 600 enables a user to monitor status, usage, and positioninformation of the tool 105 remotely via, for example, the smart phone120 or computer 135. The tool monitoring system 600 further enables auser to communicate with the tools 605 via the key fob 610.

As compared to the tool monitoring system 100 (FIG. 1), the toolmonitoring system 600 has shifted the longer range, cellularcommunication capability from the tools 105 to the gateway 615, andutilizes a shorter-range, lower cost, lower power ISM band communicationnetwork to allow the tools 605, fobs 610, and the gateway 615 tocommunicate with one another. The tools 605, fobs 610, and gateway 615make up an ISM network 616. In some embodiments, the individual ISMcommunications have a range of approximately 1000 feet, but the rangemay vary depending on obstacles, optimizations, and other factors.

In some embodiments, the tools 605 and fobs 610 have a transmit powerover the ISM network 616 of approximately +10 dbm to balance energyefficiency and communication range, while the gateway 615 has a transmitpower over the ISM network 616 of approximately +27 dbm to increasecommunication range. Various transmit power ranges may be implemented.For example, the power tools 605 and fobs 610 may have a transmit powerbetween +5 dbm to +15 dbm, less than +5 dbm, or between +15 dbm and +27dbm. Likewise, the gateway 615 may have a transmit power in the range of+15 dbm to +27 dbm, or less than 15 dbm. Generally, however, the gateway615 has an average transmit power that is greater than the transmitpower of the power tools 605 and fobs 610. Additionally, although thegateway 615 is capable of using a transmit power above +27 dbm,government regulations may prohibit such power levels for transmissionson the ISM network 616.

Additionally, the ISM network may be configured as a mesh networkimplementing a store and forward protocol. Thus, the other tools 605 andfobs 610 may serve as bridges to the gateway 615, effectively increasingthe maximum communication range between tools 605, fobs 610, andgateways 615. An example of a message communicated via thestore-and-forward protocol is described below with respect to FIG. 11A.

In some embodiments, one or more gateways 615 are positioned at aconstruction site to enable communications between the ISM network 616and a cellular network 617. The gateway 615 serves as an intermediarycommunication device allowing the tools 605 of the ISM network 616 tocommunicate with remote monitoring devices (e.g., smart phone 120, PC135, and tool monitoring server 140) via the cellular network antenna115. Accordingly, potentially expensive and higher power consumingcellular communication circuitry is limited to the gateway 615, ratherthan being within each tool 605, resulting in an overall reduction insystem costs and extended battery life of the tools 605.

The tool monitoring system 600 is scalable for use by individuals with asingle tool, contractors at a single worksite with several tools, andlarge construction companies with hundreds of tools at worksites spreadaround the world. For instance, in a small-scale implementation, thesystem 600 includes one or more fobs 610 and one or more tools 605, butdoes not include the gateway 615 or elements connected to the gateway615 (e.g., cellular network 115, PC 135, tool monitoring server 140).See, for example, FIG. 11A. In the small-scale implementation, the fob610 enables a user to wirelessly interact with and monitor the tools605, as is described in greater detail below.

FIG. 11B illustrates a medium-scale implementation, in which the fob 610is directly coupled to, or otherwise in local communication with, alocal computing device 618 (e.g., a laptop, tablet, or smart phone). Thelocal computing device 618 generally executes more powerful software andhas more powerful processing hardware than the fob 610. In addition toproviding the functions of the fob 610, the local computing device 618provides a more robust graphical user interface and additional featuresfor interacting with the tools 605 (e.g., larger tool database, moreconfigurable tool monitoring options, etc.). The fob 610 thenfacilitates the communication between the tools 605 and the localcomputing device 618. In other embodiments, the local computing device618 includes integrated ISM communications circuitry and is not coupledto the fob 610 for communicating with the ISM network 616.

The tool monitoring system 600 illustrated in FIG. 10 is considered alarge-scale implementation because it includes the gateway 615, whichconnects the ISM network 616 to the cellular network 617. In somelarge-scale embodiments, the gateway 615 is replaced or supplementedwith an embodiment of the local computing device 618 having the abilityto communicate with the cellular antenna 115, thus interfacing the ISMnetwork 616 with the cellular network 617. The system 600 is furtherexpandable to include multiple gateways 615 at a single worksite or atvarious worksites.

As shown in FIG. 12, the tool 605 is a battery-operated power drillthat, similar to tool 105, includes the tool controller 145, sensors155, battery 160, and motor 165. Although the tool 605 is depicted as apower drill in FIG. 10, other types of tools and accessories may also bemonitored by the tool monitoring system 600, such as those describedabove with respect to system 100. The tool 605 further includes atracking unit 620, rather than the tracking unit 150 of the tool 105.The tracking unit 620 is similar to the tracking unit 150, but includesan alternate wireless communication arrangement. The tracking unit 620includes an ISM antenna 625 for communication with the fob 610, gateway615, and/or other tools 605. The ISM antenna 625 is associated with anISM unit 630, which facilitates wireless transmissions via the ISMantenna 625. Similar to the tracking unit 150, while the tracking unit620 is generally powered by the battery 160, in some instances, theadditional energy storage device 230 is included. As described above,the additional energy storage device 230 enables the tracking unit 620to operate even when the battery 160 is not inserted into the tool 605.

In some embodiments, the tracking unit 620 is secured to the outside ofthe tool 605, similar to the tracking unit 550 of FIG. 8A. For instance,the mounted version of the tracking unit 620 includes a separate powersource akin to battery 565 and a mount akin to mount 570. The mountedversion of the tracking unit 620 may include sensors for monitoring thetool 605 to which it is mounted, and may be mounted to other devices aswell, such as a battery charger, battery pack, work-site radio, vehicle,ladder, construction materials, etc. Additionally, the mounted versionof the tracking unit 620 may be programmed via a wireless or wiredconnection such that the tracking unit 620 stores the type of tool ordevice to which it is secured. (e.g., drill, battery charger, ladder,vehicle, etc.) For instance, one or more of the smart phone 120,monitoring device 135, fob 610, and local computing device 618 mayinclude software for communicating with and programming the trackingunit 620. Thereafter, when transmitting the ID of the tracking unit 620,the tracking unit 620 may also identify to a receiving device the typeof tool or device to which it is attached.

Various frequency bands may be selected for communications of the ISMnetwork 616. For example, the ISM communications may occur atapproximately, 300 MHz, 433 MHz, 900 MHz, 2.4 GHz, or 5.8 GHz. Thedifferent frequency bands have various benefits. For instance, the 300MHz range allows better penetration of construction site obstacles, suchas walls, tool containers, etc. However, in some instances, governmentregulations allow more data transmissions in the 900 MHz range. Ingeneral, the ISM communications of the tracking unit 620 consume lesspower than the cellular communications of the tracking unit 150.Additionally, the ISM circuitry (e.g., ISM unit 630 and ISM antenna 625)generally has a lower cost than cellular circuitry.

The ISM frequency bands are approximate and, in practice, may havevarious ranges based on geography. For example, the 900 MHz range maymore particularly include 902 to 928 MHz in the United States and otherwestern hemisphere countries, and 863 to 870 MHz in Europe and Asia.Similarly, the 433 MHz band may include 420 to 450 MHz, the 2.4 GHz bandmay include 2.390 to 2.450 GHz, and the 5.8 GHz band may include 5.650to 5.925 GHz.

In some embodiments, the ISM communications are implemented using afrequency hopping spread spectrum (FHSS) technique. In an FHSStechnique, the transmitters and receivers in the ISM network switch overmultiple frequencies for sending and receiving communications. Forinstance, the transmitters and receivers are both aware of apre-determined sequence of frequency channel switching such that thereceivers know which frequency to be monitoring for incoming messages ata given moment in time. An FHSS transmission scheme can improve the ISMnetwork's resistance to interference and improve communication security.

The tools 605, fobs 610, and gateways 615 may further include a realtime clock for synchronizing communications over the ISM network 616.For instance, the real time clock may be used by the ISM devices todetermine precisely when to transmit and when to receive transmissions(e.g., for time multiplexed communications). In some instances,particular ISM devices are assigned receive and transmit time windows,which allows the devices to reduce power consumption as they may powerdown or enter a standby mode during periods in which the devices are notreceiving or transmitting data. Furthermore, a list of time assignmentsfor one or more ISM devices may be maintained by one or more of the ISMdevices. For instance, one of the gateways 615 may maintain a list oftime assignments of all ISM devices on the network 616.

In some embodiments, the ISM devices dynamically modify the strength oftheir wireless transmissions. For example, if a device's battery is lowthe ISM device may reduce the power at which wireless transmissions areoutput. Although the maximum distance that the wireless transmission maytravel is reduced, the time period in which the device may continue tomake these reduced power transmissions is increased. Additionally, thepower at which wireless transmissions are output may be reduced if theISM device is in close proximity to other ISM devices as determined by,for instance, signal strength. For instance, if the ISM network 616 iscontained in a small area (e.g., one room), the ISM devices may detectan unnecessarily high signal strength in their communications and, inturn, reduce their transmission power. Thus, power consumption by theISM device to carry out ISM communications is reduced. Similarly, if thesignal strength of ISM communications is detected to be low, the ISMdevices may increase the power at which transmissions are output toincrease the range of the communications.

FIGS. 13A-C illustrate the fob 610 according to some embodiments. Asshown in FIG. 13A, the fob 610 includes an energy storage device 638(e.g., a battery) for powering the other components of the fob 610. Theenergy storage device 638 may be a primary battery that is replaced upondepletion, or a secondary (rechargeable) battery. In the case of arechargeable battery, the battery may be charged in-unit by coupling thefob 610 to an external charger, or the fob 610 may include internalcharger circuitry. The charging circuitry, whether internal or external,may be coupled to a power source (e.g., an AC wall outlet, USB port,etc.). In some instances, the energy storage device 638 is temporarilyremoved from the fob 610 for recharging.

The fob 610 further includes a controller 640 in communication with amemory 642, a display 644, user input 646, user output 648, an ISM unit650, an ISM antenna 652, a USB port 654, and a power input port 656. Thememory 642 may store instructions that, when executed by the controller640, enable the controller 640 to carry out the functions attributableto the controller 640 described herein. The user output 648 includesoutput components other than the display 644, such as one or morespeakers, lights, and vibration elements to communicate with or alert auser. The power input port 656 is used to couple the fob 610 to an ACwall outlet. Transformer circuitry (not shown) may be found internal orexternal to the fob 610 to transform AC power received via the powerinput port 656 to DC power for the fob 610. The power input port 656 mayprovide power for the components of the fob 610 and charge the energystorage device 638. The USB port 654 similarly may provide power for thecomponents of the fob 610 and charge the energy storage device 638.Additionally, the USB port 654 enables the fob 610 to communicate with ahost USB device, such as the local computing device 618, as describedwith respect to FIG. 11B.

FIGS. 13B-C illustrate an exemplary fob 610 implemented with a chirpbutton 658, navigation controls 660, hand grips 662 (including ridgesfor finger placement), and an aperture 664 for receiving a key ring orotherwise attaching the fob 610 to an item. The chirp button 658 andnavigation controls 660 are part of the user input 646. In someinstances, the display 644 is a touch screen display and may replace orsupplement portions of the user input 646.

Returning to FIG. 13A, the fob 610 further includes the tool monitoringmodule 270 (see FIG. 4), which includes the tool database 285. Thenumber of tools 605 and the amount of information for each tool 605stored in the tool database 285 may be selected based on the amount ofmemory available in the fob 610. In some embodiments, information forover one hundred of the tools 605 is stored within the tool database285.

For the fob 610, the tool database 285 may be populated using one ormore techniques. For instance, the fob 610 may include a graphical userinterface (GUI) that enables a user to navigate (e.g., with navigationcontrols 660) to manually add, edit, and delete tools 605 and associatedinformation of the tools database 285. Additionally, the user cancontrol the fob 610 to perform a scan of the ISM network 616 toautomatically populate the database 285 by broadcasting an identifyrequest to the tools 605. The user may also control the fob 610 toselectively add nearby tools 605. For instance, a user can hold the fob610 near a tool (e.g., within 6, 12, or 24 in.) and navigate the GUI toselect an add-a-tool option. In this add-a-tool option, the fob 610detects the tool 605 with the strongest signal, which indicates that thetool 605 is the nearest to the fob 610, and adds the tool 605 to thetool database 285. The tools 605 may output, in response to a fob 610request, a tool identifier and other stored information (e.g., statusinformation) for purposes of adding the information to the tool database285. Further, the tool database 285 may be populated remotely by sendingtool information from the remote monitoring station to the fob 610.

As noted above, the fob 610 may communicate with the tools 605 via ISMcommunications (i.e., using ISM unit 650 and ISM antenna 652). Inaddition to populating the tool database 285, the communication may beused for tool identification, tool locating, geo-fencing, and other toolmanagement and status monitoring. Communications between the tools 605,fobs 610, and gateway 615 include messages that may include a particulardestination address (e.g., a tool/fob serial number, tool/fob ID, etc.)or may be a broadcast message (e.g., addressed to all or a subset oftools/fobs). When the controller 640 of the tool 605 receives a message,the controller 640 determines whether the message is intended for itselfbased on the destination address, if the message is intended for anothertool 605, or if the message is a broadcast message. If the message isaddressed to the particular controller 640, the message is handled asappropriate and, generally, is not repeated. However, if the message isaddressed to a different tool 605 or is a broadcast message, the tool605 will re-transmit the message. In the case of a broadcast message,the tool 605 will handle the message as appropriate in addition toforwarding the message.

Returning to FIG. 11A, an example of tools 605 a-c and the fob 610communicating over a store-and-forward mesh network is shown. In FIG.11A, the fob 610 outputs a message addressed to tool 605 c, but tool 605c is outside of the range of the initial transmission of the fob 610.However, tool 605 a is within range and receives the message. Tool 605 atemporarily stores the message, recognizes that the message is notintended for the tool 605 a, and re-transmits the message. Tool 605 breceives the forwarded message and, similarly, forwards the message.Tool 605 c then receives the forwarded message and recognizes that theforwarded message was addressed to itself (tool 605 c). The tool 605 cthen outputs a response addressed to the fob 610, which follows the samepath through tools 605 b and 605 a back to the fob 610. Assuming thateach transmission is 1000 feet in this example, the store and forwardtechnique has tripled the range of the fob 610 from 1000 feet to 3000feet. Accordingly, the store-and-forward mesh network increases thedistance over which the tools 605, fobs 610, and gateway 615 cancommunicate. Although FIG. 11A illustrates two tools 605 a-b forwardingmessages, the store-and-forward protocol generally does not limit thenumber of times a message may be forwarded.

As noted above, the fob 610 includes the tool monitoring module 270. Inthe system 100 (FIG. 1), the tool monitoring system 270 within theremote monitoring devices (e.g., smart phone 120) relied on GPS data andcellular communications with the tools. In contrast, the tool monitoringsystem 270 of the fob 610 relies on ISM communications for sendingcommands, receiving tool data, and determining tool position, forexample, based on strength of signal determinations. For example, thechirp module 297 of the tool monitoring module 270 within the fob 610communicates using the ISM network 616. A user navigates a GUI of thefob 610 to select the particular tool 605 from the tool database 285(e.g., by searching tool type or ID, scrolling, categorizing by tool, ora combination thereof), then depresses the chirp button 658. Inresponse, the fob 610 outputs a chirp message over the ISM network 616addressed to the tool 605 selected by the user.

Upon receipt by the tool 605, the tool 605 outputs a chirp noise orother audible sound to assist the user in locating the tool 605. Thetool 605 may repeatedly output the chirp noise to guide the user for apreset amount of time in response to the chirp message. Once the userlocates the tool 605, the user may depress the trigger or another buttonon the tool 605 to cease the chirp noise. In some embodiments, the tool605 includes a light that flashes and/or a vibration element thatvibrates in combination with or in place of the chirp noise to assistthe user in locating the tool 605. In some embodiments, the user mayselect via the fob 610 whether the tool 605 outputs an audible indicator(e.g., chirp, or ownership message), a visual indicator (e.g., lightflash), a tactile indicator (e.g., vibration) or a combination thereof,in response to the chirp message.

In some embodiments, the tool 605 stores an audio message in the memory225 or the memory 180 that indicates the owner or serial number of thetool 605. Upon receiving an owner request, the tool 605 outputs theaudio message (e.g., “This tool is owned by Acme Company”). In someinstances, the owner request is made by a user via an owner requestbutton (not shown) on the GUI 306 or by depressing a button on the tool605.

In some embodiments, the tools 605 include a chirp button to assist inlocating one of the fobs 610. Since a display may not be included on thetools 605, the tools 605 may store an identifier for a “home” fob 610,and depressing a chirp button of the tool 605 would cause the home fob610 to chirp. The fob 610 may be used to store the identifier of thehome fob 610 in the tool 605.

The geo-fence module 290 of the tool monitoring module 270 within thefob 610 also communicates using the ISM network 616 to, for instance,deter theft of tools 605. For example, the user may navigate the GUI ofthe fob 610 to select a tool from the tool database 285 and activate ageo-fence. The GUI and navigation controls 660 allow the user to specifya geo-fence range by, for instance, indicating a radius around fob 610in which the tool 605 is intended to operate. Thereafter, the fob 610 isin continuous or periodic communication with the tool 605 and detectsthe strength of the signal(s) from the tool 605 to estimate the distancebetween the tool 605 and the fob 610. For instance, the fob 610 mayperiodically poll the tool 605 and receive a response from the tool 605with an identifier, or the tool 605 may periodically broadcast itsidentity for receipt by the fob 610, which then detects the strength ofthe signal from the tool 605. As other tools 605 and fobs 610 may beconfigured to forward messages received as part of a mesh networkcommunication scheme (described below), a forwarded message may includean indicator signifying that the message has been forwarded and,therefore, the strength of the signal may not represent the actualdistance between the tool 605 and the fob 610.

In some embodiments, the geo-fence range is not specified by a radiusbut, rather, is the direct communication range of the fob 610. Forinstance, if the tool 605 is able to directly communicate with the fob610, rather than via message forwarding by another tool 605 or fob 610,then the tool 605 is within the geo-fence. However, if the tool 605 isnot able to directly communicate with the fob 610, the tool 605 isconsidered outside of the geo-fence.

In some instances, the geo-fence range is specified by the number ofmessage forwards over the mesh network. For instance, with reference toFIG. 11A, the tools 605 a-c may have a range specified as a singlemessage forward relative to the fob 610. Accordingly, the tool 605 a iswithin range, as it can directly communicate with the fob 610. Tool 605b is also within the geo-fence, because the fob 610 communicates withthe tool 605 b through a single message forward (by tool 605 a). Tool605 c, however, is outside the geo-fence, as a message from fob 610 mustbe forwarded twice to reach the tool 605 c—once by tool 605 a and onceby tool 605 b. When a message is forwarded by the tool 605, the tool 605may alter or add to the message to one or more of: 1) indicate that themessage has been forwarded, 2) increase a forwarded counter to indicatehow many times the message has been forwarded, and 3) include anidentifier of itself so that a future receiving device is aware of theidentity of the various devices that forwarded the message. In thegeo-fence context, as well as in other communications over the ISMnetwork 616, if the tool 605 receives a message more than once within aparticular time frame, e.g., once directly from the sending device andonce indirectly from another device, the tool 605 may ignore the second(repeat) message. In some instances, a message may include an identifierso that a receiving device can discern whether a duplicate message hasbeen received via an alternate store-and-forward path.

In some instances, tools 605 may be assigned multiple geo-fences todefine a permitted area, a warning area, and an alarm and lock-out area,as described above with respect to FIG. 5D. In some instances, multipledevices in the system 600 cooperate to triangulate the location of aparticular tool 605 using, for instance, strength-of-signaldeterminations made by the multiple fobs 610, the gateway 615, and othertools 605.

Turning to the security module 295 of the tool monitoring system 270within the fob 610, a user is able to remotely limp or lock-out one ofthe tools 605. The user may navigate a user interface of the fob 610 toselect a particular one of the tools 605, and then select a lock-outfunction. In response, the controller 640 outputs a lock-out messageaddressed to the tool 605. The lock-out message is transmitted over theISM network 616 and received by the tool 605. The tool controller 145then locks out the tool 605 to prevent further operation.

For the tool polling module 275 of the tool monitoring system 270 withinthe fob 610, a user is able to poll a tool 605 to obtain toolinformation. The user may navigate a user interface of the fob 610 toselect a particular one of the tools 605, and then select a poll toolfunction. In response, the controller 640 outputs a poll messageaddressed to the tool 605. The poll message is transmitted over the ISMnetwork 616 and received by the tool 605. The tool controller 145 thensends a response message to the fob 610 including tool information.

The tool monitoring module 270 may include additional features whenimplemented in the fob 610. For instance, the tool monitoring module 270may further include an identify module (not shown) for identifying tools605. At a worksite, a user may find a tool unattended and wish toidentify the tool. Similar to the add-a-tool technique, a user can holdthe fob 610 near the unattended tool and navigate the GUI to select anidentify option. The fob 610 may broadcast an identify request and thendetect the tool 605 that responds with the strongest signal. The tool605 responding with the strongest signal is determined to be nearest tothe fob 610. The fob 610 may then display the tool information providedby the tool 605 with the strongest signal, which will correspond to theunattended tool, along with associated tool information stored in thetool database 285. If the unattended tool is not within the tooldatabase 285, the user may opt to add it.

In some embodiments, the ISM antenna 652 of the fob 610 includes two ISMantennas 652. The two ISM antennas 652 are operable to implement radiofrequency direction finding (RFDF) to detect the direction from which RFsignals are coming. For instance, the ISM antennas 652 may use a DopplerRFDF or a very high frequency (VHF) omni-directional radio range (VOR)technique. In other words, characteristics (timing, strength of signal,etc.) of transmissions received by the two antennas are measured and adirection and distance from which the transmissions were received areextrapolated from differences in the characteristics between the twoantennas. In response, the fob 610 may display a direction pointerindicating the direction of incoming communications to assist leading auser to a particular tool 605 or other fob 610. An approximate distancethat the wireless communication traveled may also be displayed based on,for instance, a strength-of-signal analysis.

FIGS. 13D-G illustrates a smart phone 120 having an ISM case 670. Thesmart phone 120 and the ISM case 670 are collectively referred to as ISMphone 671. The ISM case 670 receives the smart phone 120 and may snaponto or have a friction fit with smart phone 120 to keep the ISM case670 secured thereto. The ISM case 670 protects the smart phone 120 fromdamage due to bumping, dropping, and other physical contact.Accordingly, the ISM case 670 includes a perimeter 672 that surroundsthe outer sides of the smart phone 120, a back 674, and, in someinstances, a clear front panel (not shown) to protect the touch-screendisplay 254. Additionally, the ISM case 670 includes an integrated ISMantenna 676 for communicating over the ISM network 616, e.g., with thetools 605, fobs 610, the gateway 615, and other ISM phones 671. In FIG.13F, the integrated ISM antenna 676 includes one or more antennas 676 inthe perimeter 672.

In the embodiments illustrated in FIGS. 13D-F, the smart phone 120communicates with the ISM case 670 via the plug 678, which is receivedvia a female port 679 on the bottom of the smart phone 120. The ISM case670 may further include a female port 680 that is similar to the femaleport 679 of the smart phone 120. The ISM case 670 may then act as apass-through for power and communications that would normally beprovided to the smart phone 120 via the female port 679. In someembodiments, the case 670 communicates with the smart phone 120 via awireless connection, such as Bluetooth®. In these instances, the case670 may include an additional antenna to enable the wirelesscommunications with the smart phone 120.

FIG. 13G illustrates the case 670 including the antennas 676, thepass-through port 680, a communication module 682, a memory 684, and acontroller 686. The memory 684 may store instructions that, whenexecuted by the controller 686, enable the controller 686 to carry outthe functions attributable to the case 670 described herein. Thecommunication module 628 enables the case 670 to communicate with thesmart phone 120, for instance, via the plug 678 and port 679 or viaBluetooth®.

The ISM phone 671 is operable to perform the functions of the fob 610.For instance, the ISM phone 671 is operable to track and communicatewith tools 605, other fobs 610, and other ISM phones 671. Additionally,the ISM phone 671 is operable to communicate on the cellular network 617via the gateway 615 or via its own cellular radio.

In some embodiments, the ISM phone 671 uses the antennas 676 toimplement an RFDF technique as described above with respect to the fob610. For instance, FIG. 13D illustrates a direction pointer 688 andapproximated distance 690 to a wireless communication source, such asone or more of the tools 605, fobs 610, and other ISM phones 671. Thedirection pointer 688 points in the direction of an ISM device emittingwireless communications. In this example, wireless ISM communicationsfrom one of the tools 605 are originating from a position approximately10 meters north-west of the ISM phone 671. A similar display includingthe direction pointer 688 and approximated distance 690 may beincorporated into the fob 610.

FIG. 14 illustrates the gateway 615 according to some embodiments. Thegateway 615 includes a translation controller 700 including a memory 705storing instructions that, when executed by the controller 700, enablethe controller 700 to carry out the functions attributable to thecontroller 700 described herein. The gateway 700 includes an ISM bandantenna 710 and ISM unit 715 (also referred to as a wireless networkmodule or an ISM module) for ISM communication; a GPS antenna 720 andGPS unit 725 (also referred to as a GPS module) for receiving GPSsignals from satellite 110; and a cellular antenna 730 and cellular unit735 (also referred to as a cellular module) for cellular communications.The components of the gateway 615 are powered via powerconverter/charger 740. The power converter/charger 740 is operable toreceive and convert power for supply to the components of the gateway615. For example, the power converter/charger 740 is coupled to AC powercord terminals 745, which may be coupled to an AC power source 750, forinstance, via a power cord. The power converter/charger 740 converts thereceived AC power to an appropriate DC power level for use by componentsof the gateway 615.

The gateway 615 further includes battery terminals 755 (i.e., a powerinterface) for receiving terminals 756 (i.e., a power source interface)of a battery 760. The battery 760 is a rechargeable and selectivelyremovable DC power tool battery, such as usable to power the tool 105and tool 605. The battery 760 may include a pack housing containingseveral battery cells, such as lithium ion or NiCad cells. In someembodiments, the battery 760 is not a power tool battery but, rather, isa primary battery or rechargeable battery of another type. When thegateway 615 is disconnected from the AC power source 750, the powerconverter/charger 740 draws power from the battery 760 for powering thecomponents of the gateway 615. When the gateway 615 is connected to theAC power source 750, the power converter/charger 740 uses the receivedAC power to charge the battery 760 (as necessary). The gateway 615further includes battery charger terminals 765 (i.e., a power interface)for coupling terminals 757 (i.e., a power source interface) of a batterycharger 770 thereto. In some embodiments, the battery charger 770 is apower tool battery charger, such as used to charge the power toolbattery 760. When coupled to the battery charger 770, however, thegateway 615 acts as a power consuming device similar to a battery beingcharged by the battery charger 770. Accordingly, the battery charger 770provides DC power to the power converter/charger 740, which is then usedto power the components of the gateway 615.

In some embodiments, the gateway 615 includes one of the batteryterminals 755 and the battery charger 770, but not both. For instance,FIGS. 15A-B illustrate the gateway 615 including battery terminals 755(not within view) for slidingly-engaging the battery 760. The battery760 includes latches 772 coupled to respective hooks 774 positionedalong respective rails 776. The gateway 615 includes grooves 778 thatcorrespond to the rails 776 for sliding engagement. When the latches 772are depressed, the hooks 774 move inward to become flush with the rails776 such that the gateway 615 may be selectively disengaged from thebattery 760. The gateway 615 further includes a data port 780, such as aUniversal Serial Bus (USB®) port. The data port 780 enables the gateway615 to communicate with devices, such as a local computing device 618,and to receive power from such devices. The data port 780 may be used toupdate firmware of the gateway 615, or to communicate data to/from thegateway 615 in conjunction with or in place of its cellularcommunications. In some embodiments, a stem-type power tool battery packhaving a projection extending away from a base of the battery pack isused, rather than the sliding groove/rail engagement system of thebattery pack 760.

In some embodiments, the battery 760 includes battery cell monitoringcircuitry to detect low charge and excessive battery temperaturesituations. In turn, the battery cell monitoring circuitry is operableto emit a battery status signal indicative of the detection to a devicecoupled thereto, such as the gateway 615. The battery status signal iscommunicated, for instance, over a data terminal of the batteryterminals 756 and battery terminals 755 of the gateway 615. In response,the gateway 615 shuts down to prevent draining the battery charge levelbelow a low threshold or heating the battery above a high temperaturethreshold, each of which could damage the battery 760.

FIGS. 16A-B illustrate the gateway 615 including battery chargerterminals 765 (not within view) for slidingly-engaging the batterycharger 770 via rails 776 and grooves (not shown). As in the embodimentsof FIGS. 15A-B, the gateway 615 of FIGS. 16A-B includes a data port 780with similar functionality.

FIGS. 16C-E illustrate a multi-bay battery charger 770 a having a rigidconstruction with a base 782 and handle assembly 784. The handleassembly 784 includes a handle 786 and connecting arms 788 that alsoprotect the multi-bay battery charger 770 a from impacts. The multi-baybattery charger 770 a includes six power source interfaces 757 forreceiving one or more power tool battery types, such as the power toolbattery 760, for recharging. Additionally, the power source interfaces757 are operable to accept and power the gateway 615, similar to thebattery charger 770 of FIGS. 16A-B. In some embodiments, the multi-baybattery charger 770 a includes more or fewer power source interfaces757, such as two, four, or eight power source interfaces. In someembodiments, the multi-bay battery charger 770 a is further able topower the gateway 615 using power from one or more battery packs coupledto the other power source interfaces 757, such as the power tool battery760.

FIG. 16D illustrates the AC power source 750, the battery 760, and thegateway 615 coupled to the multi-bay battery charger 770 a having threepower source interfaces 757 a-c, also referred to as “bays.” The ACpower source 750 supplies power to the power converter/charger 790,which charges the battery 760 and powers the gateway 615. In FIG. 16E,the AC power source 750 is not coupled to the multi-bay battery charger770 a. Rather, the gateway 615 is powered by the battery 760. In bothFIGS. 16D and 16E, the power source interfaces 757c is open, but couldaccept another battery 760 for charging or assisting in supplying powerto the gateway 615.

Returning to FIG. 14, as noted above, the gateway 615 provides aninterface between the ISM network 616 and the cellular network 617.Communications from the ISM network 616 destined for a device of thecellular network 617 (e.g., the smart phone 120) are received by thecontroller 700 via the ISM band antenna 710 and ISM unit 715. Thecontroller 700 converts the communications to a cellular protocol andtransmits the message to the cellular network 617 via the cellularantenna 730 and cellular unit 735. Communications from the cellularnetwork 617 destined for a device of the ISM network 616 (e.g., thetools 605 or fobs 610) are received by the controller 700 via thecellular antenna 730 and cellular unit 735. The controller 700 convertsthe communications to an ISM protocol and transmits the message to theISM network 616 via ISM band antenna 710 and ISM unit 715.

The gateway 615 is further operable to receive GPS signals fromsatellite 110 via GPS antenna 720 and GPS unit 725 for determining theposition of the gateway 615. For instance, the controller 700 maydetermine the position of the gateway 615 and provide the positioninformation to a user at a remote monitoring device, such as PC 135 orsmart phone 120. The user is further able to request that the gateway615 determine which tools 605 and fobs 610 are on the ISM network 616associated with the gateway 615. Accordingly, by determining where thegateway 615 is located and receiving an indication of which tools 605and fobs 610 are in communication with the gateway 615, a remote user isable to remotely determine the general location of the tools 605 andfobs 610.

Further still, the gateway 615 may determine a distance between itselfand one of the tools 605 and/or fobs 610 based on a determined strengthof signal of incoming messages from the tools 605 and/or fobs 610. Usingstrength of signal determinations enables a more precise determinationof the location of tools 605 and fobs 610. Additionally, the gateway 615may use strength of signal determinations made by other fobs 610 andtools 605 with respect to a particular tool 605 or fob 610 to belocated, in conjunction with the strength of signal determination madeby the gateway 615, to triangulate the position of the particular tool605 or fob 610. Thus, the user is able to remotely perform an inventorycheck and locate one or more tools 605 and fobs 610 that are withinrange of the ISM network 616.

Additionally, the gateway 615 may include a geo-fence module (not shown)that enables the gateway 615 to perform the geo-fence capabilitiesdescribed above with respect to the fob 610. For instance, the gateway615 may be programmed by the fob 610 or remote monitoring devices tostore one or more geo-fences with respect to one or more tools 605and/or fobs 610. The gateway 615 is able to monitor the location of theone or more tools 605 and/or fobs 610, as noted above. Upon detectingone of the tools 605 exceeding a geo-fence, the gateway 615 may takeappropriate action, such as generating an alert to one of the fobs 605and/or remote monitoring devices, locking the tool, etc.

In the system 600, the methods 340, 375, and 450 of FIGS. 6A, 6B, and 7may be implemented by the fob 610, local computing device 618, thegateway 615, one of the remote monitoring devices, or a combinationthereof. However, the tool data (including position and status data) andboundaries are obtained and monitored over the ISM network 616, ratherthan via GPS data and direct cellular communications between the toolsand remote monitoring devices. Furthermore, the user interfaceillustrated in FIGS. 5A-D may be incorporated into the fob 610, localcomputing device 618, or remote monitoring devices (e.g., smart phone120 or PC 135) of system 600 to enable the set-up of a geo-fence,monitoring of the position of the tool 605, etc., using communicationsover the ISM network 616, rather than GPS data.

The smart phone 120 and/or PC 135 in system 600 may provide a userinterface that is generally similar to that which is described above forsystem 100. For instance, the user interface of the smart phone 120described with respect to FIGS. 5A-D may be generally similar to a userinterface provided on the fob 610. However, (1) strength of signal andtriangulation techniques are used on the ISM network to locate tools 605and fobs 610, rather than GPS data, and (2) an intermediate device(gateway 615) is used to transmit and translate data communicationsbetween devices on the cellular network 617 and the tools 605 and fobs610 on the ISM network 616.

Although embodiments of system 600 have been described as includingtools 605 and fobs 610 that do not include GPS units, in someembodiments, some or all of the tools 605 and/or fobs 610 include GPSunits, similar to the tools 105 of FIG. 2, for locating, tracking, andgeo-fence purposes. However, the tools 605 and fobs 610 communicate GPSposition data across the ISM network 616 to the gateway 615 to reach thecellular network, rather than including cellular radios.

FIGS. 17A-B illustrate embodiments in which the gateway 615 is securedto a worksite radio 800. The worksite radio 800 may be a rugged radiothat is better able to withstand physical damage common at a worksiterelative to a typical portable radio. For example, the worksite radio800 may include a weather proof/resistant construction, shock absorbingelements, hard case, etc. The radio 800 may provide a physicalattachment portion 802 that enables the gateway 615 to be securelyattached to the radio 800 such that the gateway 615 will not detachthrough normal movement of the worksite radio 800. For instance, thegateway 615 may include tabs for snapping onto the radio 800, a rail andgroove arrangement for a sliding engagement, a friction fit arrangement,etc. In some instances, the gateway 615 fits into a receptacle of theworksite radio 800, which is selectively covered by a pivoting orsliding door. The radio 800 also includes a protective frame 805 thatextends above the gateway 615 to provide some level of protection to theotherwise exposed gateway 615 shown in FIG. 17B. In some embodiments,the radio 800 includes a compartment, with or without a door, padding,etc., for receiving the gateway 615 to provide an additional level ofprotection from physical damage.

In some embodiments, the gateway 615 is also electrically coupled to theradio 800 to enable the gateway 615 to receive power via the radio 800.For instance, FIG. 18 illustrates the radio 800 including a gatewayconnector 810 for selectively coupling the gateway 615 to the radio 800.For instance, the gateway 615 may be coupled to the radio 800 via one ofthe battery terminals 755 and battery charger terminals 765. The radio800 may be powered by a rechargeable and selectively removable powertool battery 815 that is coupled to the radio 800 via battery terminals820. Alternatively, the radio 800 may be coupled to the AC power source750 via AC power cord terminals 825. The radio 800 further includes apower converter/charger 830, which is similar to the powerconverter/charger 740 in that the power converter/charger 830 mayreceive power from various sources and convert the power to DC power forconsumption by other components. The power converter/charger 830provides DC power to the gateway 615 via gateway connector 810, and tothe other components of the radio 800 including radio circuitry 835,audio input/output 840, and user input/output 845. The radio circuitry835 is operable to generate audio signals in response to audio inputfrom the audio input/output 840. The audio input may include AM or FMtransmissions received via an antenna (not shown), compact discs, adigital music player (e.g., an iPod®), etc. The audio input/output 840receives the audio signals from the radio circuitry 835 and, inresponse, generates sound via speakers. The user input/output 845enables a user to select volume levels, select audio input types, andperform other common user interactions with a radio.

FIG. 19 illustrates a radio 850, which is similar to radio 800 exceptthat the gateway 615 is integrated with the radio. In other words, thegateway 615 is not selectively removable from the radio 850 withoutdisassembly. The user input/output 845 may provide a user interface tothe gateway 615 to allow a user to selectively enable, disable, andotherwise control the gateway 615.

FIG. 20 illustrates the system 600 at a worksite 860 having a building862, a fence 864 defining a perimeter around the worksite 860, a gate865, and further including puck repeaters 866 on the ISM network 616.The puck repeaters 866 receive ISM communications from the tools 605,fobs 610, or gateways 615, and re-transmit the received communicationsto other tools 605, fobs 610, and/or gateways 615 on the ISM network616. By repeating the ISM communications, the puck repeaters 866 canextend the range and improve the coverage of the ISM network 616. Thepuck repeaters 866 also perform additional functions, as describedbelow.

Turning to FIG. 21A, a controller 868 of the puck repeater 866 includesa memory 870 for storing instructions that, when executed by thecontroller 868, enable the controller 868 to carry out the functionsattributable to the controller 868 described herein. The puck repeater866 further includes a power module 872 for receiving power from one ofa battery 874 or an external power source 876. The power module 872conditions the received power and supplies the conditioned power to theother components of the puck repeater 866. The external source 876 is,for example, an external battery, power tool battery, or standard ACsource via a wall outlet. The battery 874 may be a primary battery thatis replaced upon depletion, or a secondary (rechargeable) battery. Inthe case of a rechargeable battery, the battery 874 may be chargedin-unit by coupling the puck repeater 866 to an external charger, or thepuck repeater 866 may include internal charger circuitry, e.g., in thepower module 872. In some instances, the battery 874 is temporarilyremoved from the puck repeater 866 for charging.

To repeat communications over the ISM network 616, the controller 868 ofthe puck repeater 866 receives an ISM communication and then transmitsthe same ISM communication via the ISM band antenna 710 and ISM unit715. The puck repeaters 866 can extend the range of the ISM network 616and also provide a consistent, base-line coverage zone of the ISMnetwork 616. In other words, since the puck repeaters 866 are generallyimmobile after placement, unlike the tools 605 and fobs 610, theircoverage does not generally fluctuate. Additionally, since the puckrepeaters 866 are generally immobile after placement, the complexity ofthe ISM network 616 may be simplified, particularly in the case of amesh network. That is, having mobile nodes in a network can increase itscomplexity. For instance, a communication path between a transmitternode and receiver node over a network may change over time as thetransmitter node and receiver node, as well as any nodes therebetween,vary. Accordingly, including static nodes, such as the puck repeaters866, can simplify certain communications over the ISM network 616.

In some instances, the puck repeaters 866 further include the GPSantenna 720 and GPS unit 725 such that the controller 868 of the puckrepeater 866 is operable to receive GPS data to determine the locationof the puck repeater 866. In turn, the location information of the puckrepeaters 866 is used to determine the position of other elements of theISM network 616, such as the tools 605 and fobs 610. For instance, adistance of one of the tools 605 from a puck repeater 866 may becalculated based on a determined signal strength of communicationsbetween the tool 605 and puck repeater 866. Using the combination of theGPS location data of the puck repeater 866 and the relative distance ofthe tool 605 from the puck repeater 866, an approximate location of thetool 605 is determined. Moreover, in some instances, determining thesignal strength between an ISM network device (e.g., one of the tools605) and multiple puck repeaters 866 at known positions may be used totriangulate the location of a particular device on the ISM network 616.

A portion of the puck repeaters 866 in FIG. 20 may be consideredperimeter puck repeaters 866. For instance, the puck repeaters 866secured to the fence 864 form a perimeter around a worksite 860. Acentral monitoring system, such as a remote monitoring system 120 or135, the gateway 615, the tool monitoring server 140, or the localcomputing device 618, is informed of the classification of certain puckrepeaters 866 as forming a perimeter. For instance, during setup, theperimeter puck repeaters 866 may output a perimeter signal to the ISMnetwork 616 in response to a user action (e.g., depressing a switch).Alternatively, the central monitoring system may determine thatparticular puck repeaters 866 form an outer boundary, e.g, based on GPSpositioning data, and categorize such puck repeaters 866 asperimeter-type puck repeaters 866. The perimeter-type puck repeaters 866form a virtual or geo-fence type boundary around the worksite 860 todetect tools 605, fobs 610, and gateways 615 that near or exit theworksite 860 and, in some instances, to cause a security action to betaken instantaneously or with a delay. In some embodiments, puckrepeaters 866 are positioned near exits/entrances of the worksite 860,such as the puck repeaters 866 a of FIG. 20 on both sides of the gate865.

The perimeter puck repeaters 866 are able to detect when a tool 605, fob610, or gateway 615 is near the perimeter of or has left the worksite860. For instance, if the signal strength between a particular one ofthe tools 605 and one or more perimeter pucks 866 increases to aparticular level or levels, the tool 605 is considered near theperimeter of the worksite 860. In some instances, similar to embodimentsof the fob 610, the puck repeaters 866 include two antennas such thatthey can obtain directional information, in addition to distanceinformation, for ISM devices on the network 616. In other words, thepuck repeater 866 is operable to implement radio frequency directionfinding (RFDF) to detect the direction from which RF signals are coming.Accordingly, the perimeter puck repeaters 866 are operable to determinewhen an ISM device is near or outside of the worksite 860. In responseto detecting an ISM device near or outside of the fence 864, a warningmay be given to a user of the tool 605, a security action may be taken,and/or a person or device monitoring the location of the tool 605 may benotified, similar to previous geo-fence techniques described above.

In some embodiments, one or more of the puck repeater 866, the gateway615, the fob 610, and the tool 605 includes an accelerometer to detectmotion. The motion detection capability is used to reduce powerconsumption by limiting activity of the one or more of the the puckrepeater 866, the gateway 615, the fob 610, and the tool 605. Forinstance, in some embodiments, the puck repeater 866 selectivelydetermines its GPS location based on an output of the accelerometer.When the puck repeater 866 is moving, as determined by theaccelerometer, the puck repeater 866 may periodically determine its GPSlocation and output the determined location to another device on the ISMnetwork 616. Once the puck repeater 866 ceases to move, the puckrepeater 866 may determine and output its GPS location, then cease GPSactivity until further motion of the puck repeater 866 is detected. Insome embodiments, rather than ceasing to determine and output its GPSlocation, the puck repeater 866 introduces longer delays between GPSlocation determinations. In both instances, the puck repeater 866reduces power consumption with fewer GPS location determinations.Additionally, as no motion is being detected by the accelerometer, onecan infer that the puck repeater 866 has not moved, and the most recentGPS location determined remains accurate. In some embodiments, similarstrategies for conserving power by reducing location determinations ofthe tool 605, fob 610, and gateway 615, whether by GPS or othertechniques, based on an accelerometer output are implemented.

FIG. 21B illustrates the puck repeater 866 having a generallycylindrical shape. The puck repeater 866 has a front side 888 a and aback side 888 b. The puck repeater 866 is securable via the back side888 b to a surface, such as a wall, desk/table top, ceiling within aworksite (see, e.g., the building 862 of FIG. 20). For instance, theback side 888 b includes a suction cup, an adhesive, and/or one or moreopenings or recesses to receive a screw head such that the puck repeater866 hangs from a screw previously driven into a surface. Although thepuck repeater 866 is illustrated as having a cylindrical shape, the puckrepeater 866 is constructed with a different shape, such as a cuboid oran irregular shape, in other embodiments. In some instances, the puckrepeaters 866 have increased range when positioned higher up off of theground, such as on a wall, ceiling.

In some embodiments, the puck repeaters 866 have a transmit power overthe ISM network 616 of approximately +27 dbm, similar to the gateway615. In other embodiments, a lower transmit power is used, such as to +5dbm, +10 dbm, +15 dbm, −20 dbm, +25 dbm, or another transmit power.Generally, however, the puck repeaters 866 have an average transmitpower that is greater than the transmit power of the power tools 605 andfobs 610.

FIG. 22 illustrates a tool 900 coupled to an ISM battery 902. The tool900 is able to communicate over the ISM network 616 via a connection tothe ISM battery 902. In contrast to the tool 605, the tracking andwireless communication capabilities have been moved from the tool to theISM battery 902.

The tool 900 is a battery-operated power drill that, similar to the tool105 and 605, includes the tool controller 145, sensors 155, and a motor165. Although the tool 900 is described as a power drill, the tool 900is another type of tool or accessory in other embodiments, such as thosedescribed above with respect to systems 100 and 600. The tool furtherincludes a handshake module 904 for communicating with a handshakemodule 906 of the battery controller 907, as is described in greaterdetail below. The tool 900 also includes a terminal block 908 forphysically and electrically coupling to battery terminals 910 of thebattery 902. The connection between the terminal block 908 and batteryterminals 910 enables the battery 902 to provide power to the tool 900,and for the battery 902 and the tool 900 to communicate with each other.

The battery 902 includes rechargeable battery cells 912, such as lithiumion or NiCad cells, for providing power to the tool 900 and componentsof the battery 902. The battery 902 includes the tracking unit 620 and,accordingly, is an ISM-enabled device that is able to communicate withthe fob 610 and other ISM devices on the ISM network 616. To simplifythe description, not all components of the fob 610 are illustrated inFIG. 22 and the ISM unit 650 and ISM antennas 652 are shown as a singleISM module 614.

The fob 610, battery 902, and tool 900 each store a security code 916,individually referred to as 916 a, 916 b, and 916 c, respectively. Forthe tool 900 to continue to properly operate, (a) the battery 902periodically receives the security code 916 a from the fob 610, whichmatches the security code 916 b, and (b) in turn, the battery 902periodically provides the tool 900 with the security code 916 b, whichmatches with the security code 916 c. The security code 916 may be astring of one or more of letters, numbers, symbols, etc. and may beencrypted for communications.

FIG. 23 illustrates a tether method 920 from a perspective of the tool900 and FIG. 24 illustrates a tether method 922 from a perspective ofthe battery 902. Tether method 920 begins with step 924, in which thesecurity code 916 a is stored in the tool 900. Step 924 may occur, forexample, at a point of manufacture, and the security code 916 a may bestored in a read-only memory such that the security code 916 a may notbe overwritten or changed. In step 926, the tool controller 145determines whether a trigger of the tool 900 has been depressed, orwhether the tool 900 has otherwise been activated. If the trigger isdepressed, the tool controller 145 proceeds to step 928 and initiates ahandshake with the battery 902. In the handshake, the tool 900communicates with the battery 902 to determine battery information, suchas the type of battery, the charge status of the battery, whether thebattery is malfunctioning, whether a battery error has occurred, etc.The handshake communications may be encrypted or otherwise secure.

During or after the handshake, in step 930, the tool 900 determines (a)whether a security code has been provided to the tool 900 by the battery902 and (b) if so, whether the security code provided was the securitycode 916 b, i.e., whether the security code provided matches thesecurity code 916 c stored in the tool 900. If security code 916 b hasbeen provided, the tool 900 proceeds to normal operation in step 932until the trigger is released. The released trigger is detected in step934, and the tool controller 145 returns to step 926. If, in step 930,the tool 900 determines that no security code or the incorrect securitycode was provided by the battery 902, the tool controller 145 places thetool 900 into a lock-out or limp mode. As previously described, in alock-out mode, the tool 900 is prevented from operating. For instance,the tool controller 145 does not provide motor drive control signals, orthe battery 902 is kept disconnected from the motor 165. In the limpmode, the tool 900 is able to operable, but the tool 900 has reducedperformance capabilities. In addition, in step 936, the tool 900 and/orbattery 902 may emit an audible (e.g., alarm or message), visual, ortactile signal to a user of the tool 900 that the handshake failedbecause of the mis-matched security codes 916 b and 916 c. The tool 900remains in the lock-out or limp mode until the trigger is released, asdetected in step 934. Thereafter, the tool controller 145 returns tostep 926.

FIG. 24 illustrates the tether method 922 from a perspective of thebattery 902. In step 940, the battery 902 determines whether a handshakehas been initiated by the tool 900. If a handshake has not beeninitiated, the battery controller 907 proceeds to step 942 to determinewhether (a) a communication from the fob 610 is being received thatincludes a security code and (b) if so, whether the received securitycode is the security code 916 a, i.e., whether the received securitycode matches the security code 916 b stored in the battery 900. If thefob 610 communication included the security code 916 a, the battery 902marks the security code 916 b as valid in step 944. Additionally, thebattery 902 sets a timer in step 946. The timer will indicate how oftenthe security code is to be provided to the tool 900 before a lock-out orlimp mode is activated. The time period of the timer is variabledepending on a particular implementation. For example, in someinstances, the timer is set to a short duration, such as one or fiveminutes, while in other instances, a longer timer is set, such as 12 or24 hours. Other time periods for the timer may also be selected. Thetimer begins counting down (or up) after being set in step 946, and thebattery controller 907 returns to step 940.

If, in step 942, the battery controller 907 determines that the fob 610has not communicated a security code or that the security code providedis not the security code 916 a, the battery controller 907 proceeds tostep 948. In step 948, the battery controller 907 determines whether thetimer has expired. If the timer has expired, the battery 902 marks itssecurity code 916 b as invalid in step 950. Also, in step 950, anaudible, visual, or tactile warning may be provided to the user by thebattery 902 or by the tool 900 in response to the battery 902. Forexample, a light on the battery 902 or tool 900 may be illuminated afterthe security code is marked invalid in step 950 to inform the user thathe or she should bring the tool within an acceptable range of the fob610 or ISM network 616 to receive the security code 916 before the timerexpires. In some instances, the timer may be reset at the time that thesecurity code 916 is marked invalid to ensure a minimum time periodbefore a lock-out or limp mode is enacted. If the timer is not expiredin step 948, the battery controller 907 returns to step 940.

If a handshake has been initiated, as determined in step 940, thebattery controller 907 determines whether the security code 916 b isvalid in step 952. The security code 916 b will be invalid if the timeris expired, which implies that a particular period of time has passedsince the previous instance of the fob 610 providing a matching securitycode (i.e., security code 916 a). If the code is determined to be validin step 952, the security code 916 b is transmitted to the tool 900 instep 954. In turn, the tool 900 will operate in a normal mode, asdescribed with respect to method 920 of FIG. 23. If the code isdetermined to be invalid in step 952, the security code 916 b is notoutput to the tool 900. Additionally, the battery controller 907 mayoutput an invalid code message to the tool 900, such as in step 956.Thereafter, as described with respect to method 920 of FIG. 23, the tool900 will be placed in a lock-out or limp mode. Thereafter, the batterycontroller 907 returns to the step 940 to await a further handshakerequest or fob 610 communication.

In some embodiments, the battery 902 does not determine whether it has avalid security code in step 942. Rather, the battery 902 stores asecurity code that it receives in step 942, overwriting any previouslystored security code. After a handshake is initiated in step 940, thebattery 902 bypasses step 952 to provide the currently stored securitycode to the tool 900. Thus, the tool 900, not the battery 902,determines whether the received security code is valid. Additionally,the timer is reset each time a security code is received and, if thetimer expires, the security code is erased in step 950 and not providedto the tool 900 during a handshake.

The fob 610 may be configured to communicate the security code 916 a tothe battery 902 periodically to ensure that the timer does not elapse,except when the fob 610 is out of communication range of the battery902. Thus, in effect, the fob 610 acts as a wireless tether that, if notwithin communication range of the battery 902, prevents the tool 900from normal operation. In some embodiments, the fob 610 must be able todirectly communicate the security code 916 a to the battery 902 toenable normal operation of the tool 900. That is, the security code maynot pass through other ISM devices on the ISM network 616 to reach thebattery 902, or else the security code will not be considered “correct”in step 942. However, in some embodiments, the security code 916 a maybe transmitted from the fob 610 over various ISM devices on the ISMnetwork 616 and the security code will be considered correct in step942. In some embodiments, rather than particular fob 610, the battery902 may receive the security code 916 a from another ISM device on theISM network 616, such as another tool 605, gateway 615, or puck repeater866. That is, various ISM devices may store the security code 916 a and,if the battery 902 is within range of at least one of these ISM devices,the battery 902 will have a valid security code 916 b for providing tothe tool 900 to permit normal operation thereof. In some embodiments,the battery 902 periodically outputs an ISM request for the securitycode 916 in step 942 and proceeds to step 944 or 948 depending onwhether a response with the security code 916 is provided.

In some instances, rather than a single security code 916 used by thefob 610 (or other ISM device), the tool 900, and the battery 902, thefob 610 (or other ISM device) and battery 902 use a first security code(e.g., the security code 916), while the battery 902 and the tool 900use a second security code different from the first security code.

In some embodiments, the battery 902 and method 922 are operable with atool 900 that does not store the security code (i.e., a “predecessortool” 900). For example, the predecessor tool 900 may be a previousmodel or a new model tool that is compatible with a battery similar tothe battery 902, but not having the security code functionality. Thepredecessor tool 900 and the battery carry out a handshake operationeach time the predecessor tool 900 is operated to obtain batteryinformation, but not a security code that has a time-based expiration asdescribed in methods 920 and 922. In certain instances, the battery willcommunicate an error message to the predecessor tool 900 indicating thatthe battery is not able to provide power to the predecessor tool 900.For example, if the state of charge of the battery is too low, if thebattery is overheated, or if the battery is otherwise malfunctioning,the battery may communicate to the predecessor tool 900 that the batteryis inoperable or has reduced capabilities. In response, the predecessortool 900 will not operate or will limit its performance, for instance,by reducing the output power.

The battery 902 is operable to take advantage of the handshaking abilityof the predecessor tool 900 to implement the secure tethering method922. For instance, the battery 902 may continue to execute the method922; however, in step 956, after determining that the battery 902 doesnot have a valid security code, the battery controller 907 simulates anerror message to the predecessor tool 900. Thus, the predecessor tool900 is deceived and ceases to operate or operates with reducedperformance, depending on the type of error message sent and the rulesfor handling such an error message on the predecessor tool 900.

FIGS. 25A-C illustrate a job box gateway 1000 including a job box 1001and a two-piece gateway 615 a. FIG. 26 illustrates a cross-section A-Aof the job box gateway 1000 shown in FIG. 25C. The job box 1001 is acontainer with walls 1002, handles 1004, a base 1006, and a hinged lid1008. The job box 1001 is operable to hold various tools and materialsfor a user on a worksite. The job box 1001 further includes a lockingmechanism (not shown) for selectively locking the lid 1008 shut toprevent unauthorized access to the equipment within the job box 1001. Asshown in FIG. 25A, the lid 1008 further includes a cut-out or aperture1010. The aperture 1010 enables the two-piece gateway 615 a, as shown inFIGS. 25B and 26, which includes an external portion 1012 and a internalportion 1014.

The external portion 1012 includes a mounting board 1013 and antennas1016 mounted thereon. As shown in greater detail in FIG. 28, theantennas 1016 include the GPS antenna 720, the cellular antenna 730, asecond cellular antenna 1017, and the ISM antenna 710 (see FIG. 14). TheGPS antenna 720 receives GPS signals from the GPS satellite 110. Thecellular antenna 730 and second cellular antenna 117 communicate withone or more cellular networks (e.g., network 115). The second cellularantenna 117 is optional and may be used as a redundant antenna to assistin communications with the cellular network 115. In some instances, thesecond cellular antenna 117 may be tuned slightly different than thecellular antenna 730. The ISM antenna 710 communicates with the ISMnetwork 616, which may include, for example, one or more gateways 615,batteries 902, tools 605, fobs 610, and/or pucks 886.

The external portion 1012 is covered by a dome 1018. The dome 1018 isconstructed of a rugged material, such as polyurethane, with a lowdielectric constant to improve transmission capabilities for theantennas 1016. The dome 1018 protects the antennas 1016 from damage dueto impacts, droppage, etc., which are common to a worksite. Protectivecoverings of shapes other than a dome are used in place of the dome 1018in some embodiments. Additionally, in some embodiments, another dome orprotective covering (not shown) is included within the job box 1001 toprotect the internal portion 1014.

The internal portion 1014 includes a base 1020 with an internal antenna1022, power tool battery 760, and accelerometer 1026. The power toolbattery 760 is selectively engageable with the base 1020 and providespower to the components of the gateway 615 a. The internal antenna 1022is an ISM antenna for communicating with wirelessly-enabled equipmentinside the job box 1001, such as tools 605, battery packs 902, and fobs610. The internal portion 1014 is coupled to the external portion via aconnector 1028. The connector 1028 includes data paths and/or powerconnections between the antennas 1016 and the other components of thegateway 615 a, such as the translation controller 700 and powerconverter/charger 740.

As shown in FIG. 26, fasteners 1030 extend through the base 1020,through the lid 1008, through the mounting board 1013, and terminate inflanges 1032 of the dome 1018. Thus, the fasteners 1030 secure theinternal portion 1014, the external portion 1012, and the dome 1018 tothe lid 1008 of the job box 1001. By mounting the majority of thecomponents of the gateway 615 a inside the job box 1001 and includingfasteners 1030 accessible only from the inside of the job box 1001, thegateway 615 a benefits from the transmission range of an externallymounted antenna, while still being secured against theft. In otherwords, because the lid 1008 is generally locked shut, a potential thiefis not able to access the power tool battery 760, materials within thejob box 1001, or remove the gateway 615 a, without first having theability to unlock the job box 1001.

In general, a standard job box may act as a Faraday cage that inhibitsor degrades communications between wireless devices within the standardjob box, such as the tool 605, and devices outside of the standard jobbox, such as an external gateway 615 or a component of the ISM network616. In contrast, the job box 1001 with gateway 615 a includes aninternal antenna 1022 able to communicate with wireless devices withinthe job box 1001, and external antennas 1016 for relaying communicationsto/from wireless devices outside of the job box 1001 (e.g., the cellularnetwork 115 or ISM network 616).

The internal antenna 1022 is a diversity antenna, which providesimproved communications within the job box 1001. For example, wirelesscommunications within the job box 1001 using a non-diversity antenna maybe generally difficult due to internal reflections and othertransmission/reception issues. The diversity antenna counteracts theseissues and improves communications. In some embodiments, the diversityantenna (internal antenna 1022) is circularly polarized, which providesa phase diversity antenna. In some embodiments, the internal antenna1022 has a transmit power of approximately +10 dbm or less, such as +5dbm, given the generally close proximity of communications. However, inother embodiments, the internal antenna 1022 has a transmit powergreater than +10 dbm, such as +15 dbm, +20 dbm, +25 dbm, or +27 dbm.

The accelerometer 1026 is used to detect movement of the lid 1008 and/orthe job box 1001. By monitoring an output of the accelerometer 1026, thetranslation controller 700 of the gateway 615 a is able to determinewhether the lid 1008 is open or shut, and whether the job box 1001 isstationary or moving. The gateway 615 a is operable to transmit thisinformation to external devices, such as the tool monitoring server 140,smart phone 120, PC 135, and fob 610. Additionally, the gateway 615 a isoperable to enter into a low-power mode upon detecting that the lid 1008and the job box 1001 are stationary. For example, if the lid 1008remains shut and the job box 1001 remains stationary, the gateway 615 aenters a low-power mode in which the frequency of transmissions by thegateway 615 a is reduced. Since the lid 1008 is closed and the job box1001 is stationary, the statuses of items within the job box 1001 andthe job box 1001 itself remain relatively constant, and fewertransmissions are used.

As an example, in a normal mode, the gateway 615 may transmit messagesbetween every 400 ms to 2000 ms, while in a low-power mode, the gateway615 transmits message every few minutes, 10 minutes, 30 minutes, etc. Insome instances, the frequency of transmissions by the gateway 615 a viathe internal antenna 1022 is reduced when the lid 1008 remains closed,but the transmissions by the other antennas 1016 occur at a normal rate.However, if the job box 1001 as a whole is also determined to bestationary for a predetermined time, the gateway 615 a also enters alower power mode with respect to communications via the antennas 1016.

In some embodiments, the job box 1001 and/or gateway 615 a furtherinclude the power converter/charger 740, battery charger 770 and ACpower cord terminals 745, similar to the gateway 615 shown in FIG. 14.Accordingly, the gateway 615 a is operable to be powered by an AC powersupply (e.g., from a standard AC wall outlet) and the battery charger770 is operable to charge the power tool battery 760 via power from theAC power supply.

FIG. 27 illustrates vehicle gateway 1050 having the gateway 615 aintegrated with a vehicle 1051. Similar to the job box gateway 1000, thegateway 615 a of the vehicle gateway 1050 includes the external portion1012 and the internal portion 1014 on either side of a top surface 1052,like the arrangement on the lid 1008. The top surface 1052 is part of anenclosed container 1054 of the vehicle 1051, which further includessidewalls 1056 and a bottom surface 1058. The vehicle 1051 also includesa cab portion 1060 in which a driver is operable to drive the vehicle1051. The cab portion 1060 further includes a vehicle battery 1062, suchas a 12-V DC battery. The cab portion 1060 also includes an engine (notshown) that uses fuel (e.g., gasoline, biofuel, etc.) to generaterotational mechanical energy. The mechanical energy is converted by analternator to generate electrical energy that is used to charge thevehicle battery 1062.

The vehicle battery 1062 is coupled to the gateway 615 a via a powerline 1064. The vehicle battery 1062 acts as a power source for thegateway 615 a, similar to the AC power source 750 provides power to thegateway 615 as described above with respect to FIG. 14. In other words,the vehicle battery 1062 is operable to power the gateway 615 a and toprovide power usable by the gateway 615 a to charge the battery 760. Thegateway 615 a may select which power source to use, the power toolbattery 760 or the vehicle battery 1062, based on one or both of theirrespective charge levels. For example, in some instances, the gateway615 a uses the power tool battery 760, when present, until the chargelevel drops to a certain low threshold. Thereafter, the gateway 615 auses the vehicle battery 1062, and optionally charges the power toolbattery 760. In some instances, the gateway 615 a uses power from thevehicle battery 1062 until its charge level drops to a certain lowthreshold. Thereafter, the gateway 615 a uses the power tool battery760, at least until the vehicle battery 1062 is charged by the vehicle1051 to be above a certain high threshold. In other embodiments,different powering and charging schemes using the two power sources areimplemented.

In some embodiments, the vehicle 1051 is a hybrid vehicle, electricvehicle, or another alternative fuel-type vehicle. In these instances,different battery types, fuel sources (natural gas), power generators(fuel cells, photovoltaic array, etc.) are used in the vehicle 1051.Regardless of vehicle type, however, the vehicle 1051 is operable tooutput electrical energy, whether DC or AC power, to the gateway 615 afor general power purposes and for charging the power tool battery 760.

In both the job box gateway 1000 and the vehicle gateway 1050, thegateway 615 a is positioned on an upper position (lid 1008 and topsurface 1052). Generally, the higher the gateway 615 a is positioned,the better the wireless transmission/reception available. However, insome embodiments, the gateway 615 a is positioned on a side wall, a tophalf or third of a side wall, a bottom half or third of a side wall, ora bottom surface of the job box gateway 1000 and the vehicle gateway1050. For example, in a vehicle 1051 lacking a top surface (e.g., anopen bed truck), the gateway 615 a is positionable near the top of theside wall 1056 of the truck.

The accelerometer 1026 is used in the vehicle gateway 1050 similar tohow it is used in the job box gateway 1000 to detect movement of thevehicle gateway 1050. However, the top surface 1052 of the vehicle 1051does not open; rather, the back door (not shown) opens to provide accessto tools 605, materials, etc. within the vehicle 1051. Accordingly, insome embodiments, the accelerometer 1026 is located separate from thegateway 615 a on an access door of the vehicle 1051. The accelerometerwould remain in communication with the gateway 615 a, whether wirelesslyor via wired connection, to provide acceleration signals related to boththe vehicle 1051 as a whole and the opening/shutting of the access door.The accelerometer 1026 on the vehicle gateway 1050 is, thus, similarlyable to be used to cause the gateway 615 a to enter into a low-powermode.

In some embodiments, rather than accelerometer 1026, another sensor maybe included to detect whether the lid 1008 or back door of the vehicle1051 is open and shut, such as an optical sensor or pressure sensor.However, the accelerometer 1026 may still be included on the gateway 615a to detect general movement of the job box 1001 and vehicle 1051.

FIG. 28 illustrates a block diagram of the gateway 615 a having thetwo-piece construction. As shown, the base 1020 is coupled to themounting board by the connector 1028. The gateway 615 a includesexternal power cord terminals 1064 for optionally coupling to anexternal power source, such as the vehicle battery 1062. The gateway 615a, like the gateway 615, translates messages between the ISM network 616and the cellular network 617. In some instances, the ISM antennas 1022and 710 operate on the same ISM network 616 and, for instance, messagestransmitted by the ISM band antenna 710 are also transmitted by theinternal ISM antenna 1022. In other instances, the gateway 615 aoperates on and administers two ISM networks 616, one via the internalantenna 1022, and one via the (external) ISM band antenna 710. In theseinstances, the gateway 615 a may act as an intermediary between the twoISM networks 616, or the two ISM networks 616 may remain independent. Insome instances, the ISM unit 715, GPS unit 725, and cellular unit 735are also located on the mounting board 1013. Except for the distinctionsset forth above and those apparent to one of ordinary skill in the art,the gateway 615 a and the components thereof operate generally similarlyto the gateway 615 and its components. Thus, duplicative description wasnot included.

In some embodiments, a gateway, similar to the gateway 615 or gateway615 a, is incorporated with a power distribution box, also referred toas a power box or a power box gateway. Power boxes are used as part of atemporary power system that distributes power at worksites, such asconstruction projects, particularly when a permanent powerinfrastructure is not available. A power box includes a power sourceinput for receiving temporary power from, e.g., an on-site generator orconnection to a power utility grid. A power box further includes severalstandard outlets (e.g., 120 VAC, 60 Hz) for use by construction workersfor powering various tools and items, such as power drills, saws,radios, computers, lighting, etc. A power box may have a power sourceoutput, also referred to as a daisy chain output, for daisy-chainingmultiple power boxes together.

FIG. 29 illustrates an exemplary temporary power distribution system1100. The system 1100 includes a power source 1102, at least one powerdistribution box 1110 a-c, and a plurality of power tool devices 1114,1116, 1120. The power source 1102 includes one or both of a utility gridpower source 1102 a and a mobile generator power source 1102 b. One ofthe utility grid power source 1102 a and the mobile generator 1102 b isgenerally operating, while the other is either not present in the system1100 or on standby. In some instances, the mobile generator 1102 b actsas a backup power source in case of a power outage of the utility grid1102 a.

The utility grid power source 1102 a is coupled to a local transformersubstation 1106 and provides a 50 Ampere (A), 440 volt, alternatingcurrent (VAC) power supply. The substation 1106 transforms the inputpower to one or more 50 A, 120 VAC power supply lines, one of which isprovided to the power box 1110 a. In some instances, the substation 1106is considered part of the power source 1102 a. The mobile generator 1102b is also operable to output a 50 A, 120 VAC output to the power box1110 a. The power box 1110 a receives the output of the power source1102 at an input receptacle (or power input) 1104, which is electricallycoupled to an output (daisy-chain) receptacle 1105 (i.e., a daisy-chainoutput) of the power box 1110 a. A daisy chain cable 1112 is coupled tothe daisy-chain output receptacle 1105 of the power box 1110 a and to aninput receptacle of a second power box 1110 b. A third power box 1110 cis similarly coupled by a daisy chain cable 1112 to the second power box1110 b. Thus, the output of the power source 1102 is shared among eachof the power boxes 1110. In some instances, the substation 1106 and/ormobile generator 1102 b output multiple 50 A, 120 VAC outputs, eachconnected to a separate power box 1110 or string of power boxes 1110.

The power boxes 1110 distribute the received power to various outlets oneach respective power box 1110. For example, the power distribution box1110 illustrated in FIG. 29 includes four 120 VAC outlets 1108 (alsoreferred to as AC outputs 1108) and two 5 volt, direct current (VDC)USB® type outlets 1109 (also referred to as DC outputs 1109), eachpowered by the power received at the input receptacle 1104 from thepower source 1102. At a worksite, various tools and other electronicdevices may be coupled to the 1108, 1109 of the power boxes 1110. Forinstance, in the illustrated embodiment, the power boxes 1110 arecoupled to one or more of an electric drill/driver 1114 (120 VAC), aworksite radio 1116 (120 VAC), a smart phone 1118 (5 VDC); and acircular saw 1120 (120 VAC) for providing power to each connected toolor device.

The particular voltage levels of power lines described in thisapplication are exemplary and approximate. For instance, the substation1106 may provide a single 240 VAC supply line to the power boxes 1110,or two 120 VAC supplies lines that are combined to form a 240 VAC supplyline. In such instances, the power boxes 1110 may also include one ormore 240 VAC outlets in addition to the 120 VAC outlets and 5 VDC USB®outlets. Additionally, the particular values are approximate and mayvary in practice. For instance, the 120 VAC line may be nearer to about110 VAC, and the 240 VAC supply line may be nearer to about 220 VAC.Furthermore, the power boxes 1110 are illustrated and described hereinas having common U.S.-style outlets and voltage levels. However, thepower boxes 1110 may be adapted for use with other outlet types andvoltage levels, such as those common in Japan, Great Britain, Russia,Germany, etc.

The power boxes 1110 further include a housing 1127 and a base 1128 toelevate the housing 1127 above the ground, e.g., by 2 to 18 inches. Thehousing 1127 may have a ruggedized construction including plastic and/ormetal to withstand impacts, dropping, harsh weather, moisture, and othercommon wear and tear that occurs on a worksite. The base 1128 includeslegs 1129. The base 1128, housing 1127, and legs 1129 may be integralcomponents or components that are secured to one another, e.g., viafasteners, welding, adhesive, etc. The elevation provided by the base1128 maintains the power boxes 1110 out of water, dirt, contaminants,and hazardous materials that may be found on the ground of a worksiteand that may pose issues to the power boxes 1110 and safety risks.

FIGS. 30-32 illustrate the power box 1110 including a two-piece gateway615 b. FIG. 31 illustrates a partial cross-section B-B of the power box1110 shown in FIG. 30. The power distribution circuitry of the power box1110, including circuit breakers, rectifiers, filters, outlets, etc., isnot shown in FIG. 31 to highlight the interface of the gateway 615 b andthe power box 1110. Similar to the gateway 615 a of the job box gateway1000, the gateway 615 b of the power box 1110 includes the externalportion 1012 and the internal portion 1014 on either side of a topsurface 1130 of the power box 1110, like the arrangement on the lid 1008of the job box gateway 1000. In some embodiments, the gateway 615 b ispositioned on a side wall, a top half or third of a side wall, a bottomhalf or third of a side wall, or a bottom surface of the power box 1110.

The gateway 615 b is similar to the gateway 615 a, although the gateway615 b does not include an internal ISM antenna and battery terminals755. Rather, the gateway 615 b is powered by the power source 1102. Insome embodiments, the gateway 615 b, like the gateways 615 and 615 a,translates messages between the ISM network 616 and the cellular network617. As described in more detail below, in some embodiments, the gateway615 b translates messages between the ISM network 616 and communicationnetworks other than the cellular network 617.

As shown in FIGS. 30-32, a power line adapter 1132 can be coupledbetween the power box 1110 and the power source 1102. The power lineadapter 1132 is in communication with an external network 1134, such asa local area network (LAN), wide area network (WAN), the Internet 125,or a combination thereof. The network 1134 enables the adapter 1132 tocommunicate with remote devices coupled thereto, such as the toolmonitoring server 140 and PC 135. The adapter 1132 includes a modem (notshown) to enable communication with the network 1134. In some instances,the modem has a separate housing that is external to a housingcontaining other components of the adapter 1132.

The adapter 1132 is operable to provide a communication bridge betweenthe network 1134 and the gateway 615 b of the power box 1110.Accordingly, the gateway 615 b is operable to communicate with theInternet 125, tool monitoring server 140, and PC 135 (see FIG. 10)through a non-cellular path (power lines).

FIG. 32 illustrates a block diagram of the gateway 615 b having atwo-piece construction. As shown, the base 1020 is coupled to themounting board 1013 by the connector 1028. The gateway 615 b includes apower-line adapter 1142 coupled between the translation controller 700and the power-line adapter 1132.

The power-line adapters 1132 and 1142 are operable to communicate overthe power line 1344. In other words, the power line 1344 carries both ACpower (e.g., 120 VAC) and data communication signals. For example, theadapters 1132 and 1142 may follow the IEEE 1901 communication protocolfor communicating data over the power line 1344. Thus, the power-lineadapters 1132 and 1142 and power line 1344 provide a communicationbridge between the translation controller 700 and the network1134/Internet 125. Accordingly, the tool monitoring server 140 and PC135 are operable to communicate with power tools 605 and batteries 902(power tool devices) of the ISM network 616 via the gateway 615 b usingISM and cellular communications and/or with ISM and data-over-power-linecommunications. In some instances, the cellular antennas 730 and 1017are not included in the gateway 615 b because the translation controller700 relies instead on the power-line adapter 1142 for communicating withthe network 1134 or Internet 125.

The gateway 615 b further includes a power converter 1146 for receivingand conditioning the AC power from the AC source 1102 for use by thevarious components of the gateway 615 b, such as the translationcontroller 700. The power connections between the power converter 1146and the components of the gateway 615 b are not shown in FIG. 32 tosimplify the illustration.

Except for the distinctions set forth above and those apparent to one ofordinary skill in the art, the gateway 615 b and the components thereofoperate generally similarly to the gateways 615 and 615 a and theircomponents. Thus, duplicative description was not included.

In some embodiments, the power box 1110 includes a physical attachmentportion for receiving the gateway 615 similar to a physical attachmentportion 802 of the worksite radio 800 illustrated in FIGS. 17A-B. Thepower box 1110 provides power to a connected gateway 615 via terminalsof the physical attachment portion 802, i.e., a power source interface.The physical attachment portion 802 enables the gateway 615 to besecurely attached to the power box 1110 such that the gateway 615 willnot detach through normal movement of the power box 1110. For instance,the gateway 615 may include tabs for snapping onto the power box 1110, arail and groove arrangement for a sliding engagement, a friction fitarrangement, etc. In some instances, the gateway 615 fits into areceptacle of the power box 1110, which is selectively covered by apivoting or sliding door. In some embodiments, the power box 1110includes a compartment, with or without a door, padding, etc., forreceiving the gateway 615 to provide protection from physical damage.

The controllers described herein, including controllers 145, 220, 640,700, 868, and 907 may be implemented as a general purpose processor,digital signal processor, application specific integrated circuit(ASIC), or field programmable gate array (FPGA), or a combinationthereof, to carry out their respective functions.

Thus, the invention provides, among other things, systems and methodsfor remotely tracking power tools and related devices.

In one embodiment, the invention provides a power distribution boxgateway including a power source input receptacle, a plurality ofalternating current (AC) output receptacles, a daisy-chain outputreceptacle, and a gateway device. The power source input receptacle hassource terminals to receive a power cable supplying power from anexternal power source. The plurality of AC output receptacles areelectrically coupled to the source terminals of the power source inputreceptacle. The daisy-chain output receptacle is connectable to a secondpower source input of a second power distribution box. The gatewaydevice is coupled to the source terminals for receipt of power andincludes a wireless network module and a cellular module. The wirelessnetwork module is configured to wirelessly communicate with a wirelessnetwork having at least one power tool device. The cellular module isconfigured to wirelessly communicate via a cellular network.

In some instances, the power distribution box gateway further includes ahousing portion and a base portion. The housing portion includes thepower source input receptacle, the plurality of AC output receptacles,the daisy-chain output receptacle, and the gateway device. The baseportion elevates the housing portion above a surface on which the powerdistribution box is placed. In some instances, the power distributionbox gateway further includes a gateway connector for selectivelyattaching the gateway to the housing. In some instances, the powerdistribution box gateway further includes a housing portion including arecess on an outside surface of the housing portion and a power sourceinterface in the recess. The gateway device is selectively insertableinto the recess and includes a power interface configured to engage thepower source interface to receive power.

In another embodiment, the invention provides a power distribution boxgateway including a power source input receptacle, a plurality ofalternating current (AC) output receptacles, a daisy-chain outputreceptacle, and a gateway device. The power source input receptacleincludes source terminals to receive a power cable supplying power froman external power source. The plurality of AC output receptacles areelectrically coupled to the source terminals of the power source inputreceptacle. The daisy-chain output receptacle is connectable to a secondpower source input of a second power distribution box. The gatewaydevice is coupled to the source terminals for receipt of power andincludes a wireless network module and a power-line adapter. Thewireless network module is configured to wirelessly communicate with awireless network having at least one power tool device. The power-lineadapter is configured to communicate over the power cable.

In some instances, the power distribution box gateway further includes ahousing portion and a base portion. The housing portion includes thepower source input receptacle, the plurality of AC output receptacles,the daisy-chain output receptacle, and the gateway device. The baseportion elevates the housing portion above a surface on which the powerdistribution box is placed. In some instances, the power-line adapter isin communication with an external power-line adapter, which is incommunication with a computer network. In some instances, the power-lineadapter communicates data related to the at least one power tool deviceto a remote device over the computer network. In some instances, thepower-line adapter communicates data related to the at least one powertool device via the power cable.

Various features and advantages of the invention are set forth in thefollowing claims.

What is claimed is:
 1. A power distribution box comprising: a powerinput configured to receive power from an external power source; a firstpower output electrically coupled to the power input, the first poweroutput configured to provide power to an external device; and a gatewaydevice including a wireless network processing unit includingelectronics and configured to communicate with at least one power tooldevice in a wireless network, an external network interface configuredto communicate with an external network, a translation controllerincluding electronics and enabling communications between the wirelessnetwork processing unit and the external network through the externalnetwork interface, and a physical attachment portion configured toremovably secure the gateway device to the power distribution box. 2.The power distribution box of claim 1, wherein the external networkinterface includes a power line adapter coupled to the power input, andthe external network interface is configured to receive power throughthe power input, and communicate with an external network.
 3. The powerdistribution box of claim 1, wherein the external network interfaceincludes a cellular processing unit including electronics, and theexternal network interface is configured to communicate with theexternal network through cellular communications, wherein the externalnetwork is a cellular network.
 4. The power distribution box of claim 1,wherein the power distribution box provides power to the gateway devicevia terminals of the physical attachment portion.
 5. The powerdistribution box of claim 1, wherein the gateway device includes atleast one selected from the group consisting of tabs for snapping ontothe power distribution box, a rail and groove arrangement for a slidingengagement to the power distribution box, or a friction fit arrangementfor attaching the gateway device to the power distribution box.
 6. Thepower distribution box of claim 1, wherein the gateway device fits intoa receptacle of the power distribution box, which is selectively coveredby a door.
 7. The power distribution box of claim 3, wherein the gatewaydevice includes at least one antenna for communicating via the wirelessnetwork processing unit and via the cellular processing unit, the atleast one antenna covered by a protective covering made of ruggedmaterial with a low dielectric constant.
 8. The power distribution boxof claim 1, wherein the translation controller translates messagescommunicated between the at least one power tool device and the externalnetwork, the external network comprising at least one power toolmonitoring system.
 9. A method for communicating by a power distributionbox, the method comprising: receiving power from an external powersource via a power input of the power distribution box; providing powerto an external device via a first power output of the power distributionbox, the first power output coupled to the power input; communicatingwith at least one power tool device in a wireless network via a wirelessnetwork processing unit in a gateway device of the power distributionbox; communicating with an external network via an external networkinterface of the gateway device of the power distribution box; andtranslating data communications by a translation controller coupled tothe wireless network processing unit and the external network interfaceto enable communication between the wireless network processing unit andthe external network through the external network interface.
 10. Themethod of claim 9, wherein the external network interface includes apower line adapter coupled to the power input, and the external networkinterface is configured to receive power through the power input, andcommunicate with the external network.
 11. The method of claim 9,wherein the external network interface includes a cellular processingunit including electronics and the external network interface isconfigured to communicate with the external network through cellularcommunications, wherein the external network is a cellular network. 12.The method of claim 9, further comprising: receiving, at a physicalattachment portion of the power distribution box, the gateway device tothe power distribution box, and providing power by the powerdistribution box to the gateway device via terminals of the physicalattachment portion.
 13. The method of claim 9, further comprising:receiving, in a receptacle of the power distribution box, the gatewaydevice; and selectively covering the receptacle, and the gateway devicetherein, with a door of the receptacle.
 14. The method of claim 9,wherein communicating via the wireless network processing unit or thecellular processing unit includes communicating via at least one antennaof the gateway device that is covered by a protective covering made ofrugged material with a low dielectric constant.
 15. The method of claim9, wherein messages, communicated between the at least one power tooldevice and a power tool monitoring system that is communicativelycoupled to the external network, include location data indicative of alocation of the at least one power tool device or operational dataassociated with the at least one power tool device.
 16. A powerdistribution box comprising: a power input configured to receive powerfrom an external power source; a first power output electrically coupledto the power input, the first power output configured to provide powerto an external device; and a gateway device including a wireless networkprocessing unit including electronics and configured to communicate withat least one power tool device in a wireless network, an externalnetwork interface configured to communicate with an external network,and a translation controller including electronics that is coupled tothe wireless network processing unit and the external network interface,and that is configured to translate data communications to enablecommunications between the wireless network processing unit and theexternal network through the external network interface.
 17. The powerdistribution box of claim 16, wherein the external network interfaceincludes a power line adapter coupled to the power input, and isconfigured to receive power through the power input, and communicatewith the external network.
 18. The power distribution box of claim 16,wherein the external network interface includes a cellular processingunit including electronics, and is configured to communicate with theexternal network through cellular communications, wherein the externalnetwork is a cellular network.
 19. The power distribution box of claim16, further comprising a physical attachment portion configured toremovably secure the gateway device to the power distribution box. 20.The power distribution box of claim 16, wherein the power distributionbox provides power to the gateway device via terminals of the physicalattachment portion.